Method and apparatus for producing finished foam containers

ABSTRACT

The present invention is directed to an improved apparatus and method for manufacturing completed foam plastic containers. An endless mandrel chain carries cup forming mandrels along a manufacturing path. After each mandrel is preheated, a bottom blank is placed on the mandrel bottom and held there by a vacuum. A cylindrical blank formed from longitudinally stretch-oriented foam sheet material is then placed onto the mandrel. This cylindrical blank is tightly tamped onto the mandrel and is clamped in place. Radiant heat is then used to shrink form a finished container. The bottom is then sealed to the cylindrical blank and the mandrel is transferred to a curling assembly where the top edge portion of each finished container is lubricated and then curled to form a finished rim. The apparatus of the present invention may form containers having a dual tapered configuration which allows the containers to be more tightly stacked.

This application is a continuation of application Ser. No. 219,520 filed12/23/80, abandoned, which application is a continuation-in-part ofapplication Ser. No. 953,620, filed Oct. 23, 1978, now U.S. Pat. No.4,306,849 which is a continuation-in-part of application Ser. No.665,617, filed Mar. 10, 1976, now U.S. Pat. No. 4,121,402.

FIELD OF INVENTION

This invention relates to a method and apparatus for forming finishedcontainers and more particularly, to a method and apparatus for formingfinished containers from heat shrinkable material such as foam plasticsheets or the like.

BACKGROUND OF THE INVENTION

It is known in the art to shrink formed containers such as drinking cupsfrom preformed tubular lengths of circumferentially orientedthermoplastic material such as foam polystyrene.

One particularly desirable method of initially forming a tubular lengthof such circumferentially oriented material is to provide rectangularpreprinted blanks and wrap these blanks around a mandrel whereon a heatsealed seam is effected longitudinally along the circumference of theformed tubular lengths. The use of rectangular blanks facilitatespreprinting of patterns, designs, logos, etc. on the blanks such thatthe ultimate tubular links and containers formed therefrom will bear theultimately desired indicia.

A further advantage of the rectangular blank is that it may be cut froman extruded sheet of thermoplastic or thermoplastic foam which isstretched longitudinally, i.e., in the most logical, natural and faciledirection of stretch after extrusion, namely, the machine direction, toachieve the necessary circumferential orientation in a tubular length orcylinder formed from the rectangular blank.

Previous efforts to handle these rectangular blanks and form them intocylinders, however, have required relatively elaborate systems oftransfer rollers, turrets with multiple mandrels thereon and vacuumsystems to properly index leading and/or trailing edges of therectangular blanks on the transfer rollers or mandrels.

OBJECTS OF THE INVENTION

It is, therefore, an object of the present invention to provide a newand novel improved method and apparatus for manufacturing finishedcontainers from rectangular blanks of heat-shrinkable plastic materialsuch as foamed polystyrene.

Another object of the present invention is to provide a new and improvedmethod and apparatus for converting a cylindrical blank into a finishedcontainer.

It is a further object of the present invention to provide a method andapparatus for producing a finished container having a neatly curled topedge portion.

It is a still further object of the present invention to provide a newand improved method and apparatus for producing finished containers moreefficiently than the apparatuses heretofore utilized in the prior art.

These and other objects of the present invention will become more fullyapparent with reference to the following specification and drawingswhich relate to preferred embodiments of the present invention.

SUMMARY OF THE INVENTION

A convolute roll of elongated preprinted stock of longitudinallyoriented heat shrinkable material such as polystyrene foam sheet isformed into a cylindrical container blank. Similarly, a disc shapedbottom blank is also formed from a like material.

A series of final forming mandrels are carried on an endless chain orturret and are shaped in cross-section like a desired ultimate containersuch as a cylindrical food can with a rounded bottom edge or afrustro-conical drinking cup. In a preferred embodiment, the mandrelshave the shape of a dual tapered frustro-conical drinking cup. This dualtaper of the mandrel allows the finished container to also be dualtapered, allowing a plurality of the finished containers to have areduced stack height for shipping and distribution. This dual taperedfeature is also used to prevent the stacked cups from sticking together.A bottom blank may be placed on each of the final forming mandrels andheld there by vacuum while the sidewall of the ultimate container,namely, the cylindrical blank is transferred from a cylindrical blankforming station onto the final forming mandrel.

As the mandrel is driven by endless chain or a rotary turret, themandrel moves to a cylindrical blank tamper assembly which tamps thecylindrical blank securely onto the final forming mandrel upon whichclamps are provided to securely fasten the cylindrical blank.

The mandrel then moves past a series of radiant heaters whichprogressively shrink and soften the bottom blank and cylindrical blankto form a container having a shape corresponding to the final formingmandrel.

In all cases, in the preferred embodiments of the present invention, thecylindrical blanks exceed the axial length of the final forming mandrelssuch that the bottom edge of the sidewall shrinks around the outer edgesof the bottom blank to provide a heat-sealable bottom seam. The finalheat sealing is effected by any suitable heating means such as aconformally shaped bottom ironer.

In the preferred embodiments of the present invention, a generallyfrustro-conical or cup-shaped container is desired. The final step inthe process of producing such a cup shaped container is the forming of atop curl or bead to increase the lateral stiffness and drinking comfortof the container. To facilitate this purpose, the finished uncurledcontainer is transferred to a curling pot which travels along an endlesscurling pot chain. The top edge portion of the finished but uncurledcontainer is then coated with a thin deposit of mineral oil by a curlingoil applicator. A top curl is then formed by the curling apparatus whichrolls the bead of the container. The container is then removed from thecurling pot and is packaged in any desirable manner.

The present invention allows rolls of material for a large number ofcontainers to be stored in much less space than that required forcontainers. The containers may be either efficiently stacked or may beused as they are made, solving the problem in inventories and supply ofpreviously manufactured containers for a food processing type user.

Further scope of applicability of the present invention will becomeapparent from the detailed description given hereinafter. However, itshould be understood, that the detailed description and specificexamples, while indicating preferred embodiments of the invention, aregiven by way of illustration only, since various changes andmodifications will become apparent to those skilled in the art from thisdetailed description.

BRIEF DESCRIPTION OF THE DRAWINGS

The present invention will become more fully understood from thedetailed description given hereinbelow and the accompanying drawingswhich are given by way of illustration only, and thus are not limitativeof the present invention, and wherein:

FIG. 1 is a top plan view of a blank handling cylinder forming andcylinder transferring mechanism of the present invention;

FIG. 2 is a side elevation of the feed roll, rotary cutter and rightangle transfer belts of the present invention;

FIG. 2A is a top plan schematic illustrating the stretch orientation ofcut rectangular blanks as they undergo the right angle transfer from therotary cutter to the cylinder forming means of the present invention;

FIG. 3 is an exploded schematic illustrating in correlated cross sectionthe various forming stages of the present invention in converting arectangular blank into a cylinder by continuous movement of the blankalong a fixed mandrel;

FIG. 4 is a schematic side elevation of a forming mandrel drive,transfer station and forming oven of the present invention;

FIG. 5A is a detail of a forming mandrel, mount and drive chain in sideelevation;

FIG. 5B is a top elevation of the detail of FIG. 5A with an alternateform of forming mandrel shown in dotted lines therein;

FIG. 6A is a cross section of a frustro-conical mandrel illustratinginternal vacuum ports therein and a container formed thereon;

FIG. 6B is a cross section of a substantially cylindrical mandrelillustrating internal vacuum ports therein and a container formedthereon;

FIG. 7 is a schematic of a cup making system of the present invention;

FIG. 8A is a top view of a vacuum distributor of the present invention;

FIG. 8B is a side elevation in cross section of the vacuum distributorof FIG. 8A taken along line 8B--8B of FIG. 8A;

FIG. 9 is a top plan view of bottom finishing, top curl forming andcontainer ejection stations for cup making equipment of the presentinvention together with a bottom blank feeding station;

FIG. 10 is a cross-sectional view of the top curl forming station takenalong line 10--10 of FIG. 9;

FIG. 10A is an enlarged view of the top curl tool;

FIG. 11 is a cross section of the bottom finishing station taken alongline 11--11 of FIG. 9;

FIG. 11A is an enlarged cross-sectional illustration of a bottom ironengaging a container bottom on a mandrel of the present inveniton duringbottom sealing;

FIG. 11B is a top plan view of the bottom iron of FIGS. 9, 10, 11, and11A;

FIG. 12 is a cross section taken along line 12--12 of FIG. 9;

FIG. 13 is a schematic of a container filling station;

FIG. 14 is a schematic of a filled container capping station;

FIG. 15 is a schematic of a filled container capping stationillustrating a different cap or lid from that illustrated in FIG. 14;

FIG. 16A is a top plan view of a bottom blank handling apparatusaccording to the present invention;

FIG. 16B is a continuation of the top plan view of a bottom blankhandling apparatus as illustrated in FIG. 16A;

FIG. 16C is a continuation of a bottom blank handling apparatus asillustrated in FIGS. 16A and 16B and further illustrating the bottomblank web feed mechanism;

FIG. 17A is a side elevation of the bottom blank handling apparatus asillustrated in FIG. 16A;

FIG. 17B is a side elevation of the bottom blank handling apparatus asillustrated in FIG. 16B;

FIG. 17C is a side elevation of the bottom blank handling apparatus asillustrated in FIG. 16C;

FIG. 18 is a side view of the rotary die and illustrating a partialcross-section view of the framework;

FIG. 19 illustrates a side cross-sectional view of the mandrel assemblyof the present invention;

FIG. 19A illustrates the scallop detail formed in the mandrel of FIG.19;

FIG. 19B discloses a 180° rotation (counterclockwise) of a detail of avacuum valve shown in FIG. 19;

FIG. 20 shows an end view of the mandrel assembly of FIG. 19;

FIGS. 21 and 21B collectively illustrates a side plan view of thedetailed disclosure of a cylindrical tamper apparatus of the presentinvention;

FIG. 22 illustrates a top plan view of the cylindrical tamper apparatusillustrated in FIG. 21;

FIG. 23 illustrates a front view of a curler frame and drive assembly;

FIGS. 24A and 24B collectively illustrate a side cross-sectional view ofa curling apparatus illustrated in FIG. 23;

FIG. 25 is a diagrammatic view of the curler drive assembly includingcurler cam timing information;

relation

FIGS. 25A-E illustrate diagrammatic details of the relationship betweena driven curl-forming iron TC, a fixed curling anvil 440 and a containerformed according to the present invention;

FIG. 26 is a top plan view of a detailed embodiment of a curling oilapplicator apparatus according to the present invention;

FIG. 27 is a front plan view of a detailed embodiment of the curling oilapplicator apparatus illustrated in FIG. 26;

FIG. 28 illustrates a top plan schematic illustrating the curling oilapplicator apparatus of the present invention including a cup feeder andits associated cam;

FIG. 29 is a plan view of a detailed preferred embodiment of a completecup-making apparatus for producing completed foam plastic containersfrom rectangular blanks according to the present invention;

FIG. 30 is a schematic of the complete cup-making apparatus of FIG. 29which illustrates the placement of a preferred embodiment of the shrinkoven which utilizes a plurality of radiant panel heaters;

FIGS. 30A-C are sections of the schematic of FIG. 30 showing therelative placement of the radiant panel heaters in relation to a formingmandrel;

FIG. 31 is a front plan view of an alternate large rotating turretembodiment of the completed cup-making apparatus of the presentinvention; and

FIG. 32 is a side plan view of the alternate large rotating turretembodiment of the completed cup-making apparatus of the presentinvention.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

Referring to FIGS. 1 and 2 the material 10 from which the intermediatecylinders and ultimate containers are to be made is shown as anelongated strip convolutely wound in the form of a large supply roll 12rotatably mounted on a suitable stanchion or support 14.

The feed material 10 is unwound from the supply roll 12 and passedbeneath a tension roller 16 (FIG. 2) and a guide roller 18 into contactwith a vacuum feed drum 20 which cooperates with a synchronized rotarycutter means 22 to sever the end of the feed material 10 into uniformrectangular blanks 1OA.

The feed material 10 is stretch oriented for enhanced heat shrinkcharacteristics in the direction 10B which is parallel to the longdimension of the ultimate rectangular blanks 10A.

As the blanks 10A are released from the downstream side of the vacuumdrum 20, the latter being flanged at 20A, 20B to contain the narrowerwidth of the feed material 10 between the flanges 20A, 20B as shown inFIGS. 1 and 2, an upper pinch roll 24 and blank bottom engaging pair ofdrive belts DB1A and DB1B entrain the leading edge of each successiveblank 1OA. Each blank 10A is fed on its longnitudinal axis by the drivebelts DB1A, DB1B beneath a biased retaining guide 26 to a right angletransfer point TP2.

At the transfer point TP2 a set of cross feed belts CFB are locatedadjacent a limit stop means LS which abuts with and positions eachrectangular blank 1OA for lateral transfer by the said cross-feed beltsCFB.

The drive belts DB1A and DB1B pass at an angle through suitable slots inthe surface of a transfer table TT such that prior to engaging the limitstop LS the blanks 1OA have been accelerated by and broken contact withthe drive belts DB1A and DB1B.

As shown in FIG. 3, the cross-feed belts CFB are mounted to pivot towardand away from the upper surface of the transfer table TT in synchronismwith the forming of the rectangular blanks 10A and their delivery to thetransfer point TP2. Thus, each said blank 10A will be transferredlaterally of its longitudinal axis substantially instantaneously uponengaging the limit stop LS at the transfer point TP2.

The pivotal motion of the cross-feed belt assembly CFB is effected bymeans of a drag link 28 and crank arm 30 acting about a pivot point 32as illustrated in FIG. 3.

The cross-feed belts CFB drive the blanks 10A off the transfer table TTonto a carrier chain 34 having pushers or dogs 36 thereon which engagethe trailing edges of the blanks 10A and propel them along in adirection transverse to their longitudinal stretch orientation direction10B.

Longitudinally disposed along the upper reach of the carrier chains 34is a hollow tubular forming mandrel M which is fixed against rotation ina suitable holding bracket 40.

Leading into a bracket 40 and progressively varying in shape along thesubstantially entire extent of the forming mandrel M are opposed formingrails FR1, the extent of which can best be understood with reference toFIGS. 1 and 3.

As the carrier chain 34 progresses clockwise around the chain drivesprockets 38A, 38B, the pusher dogs 36 move the blanks 10A through theforming rails FR1 to bend the blanks 10A in stages 10A1 into a u-shaped1OA3 about the mandrel M with the legs of the u-shaped blank 10A3 beingadjacent to elongated external and internal surface heaters H1 and H2,respectively, the "external" surface being the outer surface of theinnermost lap L1 of a side seam and the "internal" surface being theinner surface of the outer lap L2 of the side seam as shown in thesubstantially cylindrical fold 10A4 of the blank 1OA effected by meansof folding rails FR2 downstream from the heaters H1, H2.

A heater H3, schematically shown in FIG. 3 can be utilized to provideadditional heat such as radiation or force hot air between the nearlyjuxtaposed laps L1 and L2.

When the cylindrical fold is completed the rectangular blank 1OA hasbeen converted into a cylindrical 10C which exists the folding rails FR2and passes under a pressure belt assembly PB which applies sufficientdownward pressure on the laps L1-L2 to form a heat-sealed lapped sideseam SS in the cylinder 10c while at the same time translating thecylinder 10c off the mandrel M and onto a finishing mandrel FM.

Referring to FIGS. 3, 5A and 5B, the finishing mandrels FM are shown insolid lines as having a frusto-conical (drinking cup) shape and indotted lines as having a substantially cylindrical shape FM1 similar tothat of pressurized aluminum beverage cans.

The finishing mandrels FM are mounted on one end of support arms 44which are mounted at their other ends on a drive chain 46 which passesabout a main transfer sprocket 48 adjacent the finish end of theelongated forming mandrel M. As shown in FIGS. 1 and 3, the finishedcylinders 10C are stripped from the forming mandrel M onto one of thefinishing mandrels FM which is in substantially coaxial registry withthe forming mandrel M.

This registry is achieved by proportioning the transfer sprocket 48 suchthat the arms 44 are radii thereof and place the finishing mandrels FMone-by-one at the dead center position 48A of the transfer sprocket 48at the point of coaxial registry with the forming mandrel M. As aresult, a time delay during which the finishing mandrel FM remains insuch registry is effected, thereby permitting transfer of the cylinder10C from the forming mandrel M onto the finishing mandrel FM. In anotherembodiment the registry of the finishing mandrel may be effected bysynchronization of the discharge of the cylinder 10C from the formingmandrel M onto the finishing mandrel FM.

Once the cylinders are transferred onto the finishing mandrels FM theyare conveyed on those mandrels through a suitable heat tunnel HT, thelength of the latter and its temperature being correlated with the speedof the carrier chain 46 to shrink the cylinders to a frusto-conicalconfiguration or a cylindrical configuration depending upon the shape ofthe finishing mandrel FM or FM1.

The shrinkable sleeves SS are longer than the mandrels FM, FM1 so as toshrink beneath the bottom defining ends of the mandrels (provide theinturned bottom or curl) of a finished container.

For example, as shown in FIG. 6A, a frusto-conical sidewall SW1 isproduced by shrinking the sleeves SS on a fusto-conical mandrel FM. Abottom blank BD is provided such that the inturned edges SW1A of thesidewall SW1 will overlap the bottom blank BD after forming the sidewallfrom the sleeve SS.

The mandrel FM is shown as including internal vacuum ports VP whichextend to a vacuum connection VC on the mounting arm 44 of the mandrelsas will be more fully described with reference to FIG. 7.

For a container of a more conventional cylindrical shape such as thecross section of an aluminum beverage can or the like, reference is madeto FIG. 6B in which a more cylindrical mandrel FM1 having vacuum portsVP1 is shown with a sidewall SW2 shrink formed thereon with inturnededges SW2A overlapping the periphery of a bottom blank BD1, the latterbeing initially held on the mandrel via the vacuum ports VP1.

Referring now to FIG. 7, the finishing mandrels FM (provided with abottom blank BD as shown in FIG. 6A and to be more fully described withreference to FIGS. 9-11) are loaded with the shrinkable cylinders at aloading station LS1 in the manner previously defined in FIGS. 1-6, andthe mandrels FM bearing the sidewall blanks (SW1) are progressivelytransported through the heat tunnel HT from the entrance HT1 thereof tothe exit HT2 on the carrier chain 46 over the drive sprockets 48.

When the mandrels FM leave the exit HT2 of the heat tunnel HT they arecarrying formed cups or containers of the configuration shown in FIG.6A. These cups or containers are then subjected to bottom sealing and atop curl forming operation as will be described with reference to FIGS.9-11.

The bottom blanks BD (BD1) of FIG. 6A (6B) are held on the mandrels FM(FM1) by means of vacuum applied through vacuum hoses VH. The vacuumhoses VH are in communication with ports VP (VP1) thorugh the supportarms 44 and said mandrels.

A vacuum distributor VD is provided centrally of the arcuately disposedheat tunnel HT. All of the vacuum hoses VH are manifold into the vacuumdistributor VD.

As further shown in FIGS. 8A and 8B, the vacuum distributor VD includesa top rotor plate VD1 having a plurality of radially disposed vacuumports VPR. Each of the vacuum hoses VH is connected to a vacuum port VPRwhich in turn is in communication with a circular locus in the rotordisc VD1 which corresponds in size to the radius of an arcuate vacuumsupply port VSP in a fixed bottom plate VD2 through which an inputcoupling VIC is provided to connect the supply port VSP to a vacuumsource VS.

As the mandrels FM travel through the heat tunnel HT, the rotor disc VD1rotates on a bearing VB on a support shaft VSS and is held in sufficientsealed engagement therewith. The vacuum ports VPR in the rotary disc VD1thus come into and out of registry with the vacuum supply port VSP inthe support disc VD2 causing vacuum to be applied through the hoses VHto the vacuum ports VP (VP1) in the mandrels FM (FM1) to provide thesuction required to hold the bottom blanks BD (BD1) in place on the saidmandrels pending the shrink forming of the sidewall blanks SW1 (SW2) tooverlap the bottom blanks BD (BD1) at the inturned portions SW1A (SW2A)of the said sidewall blanks.

The arcuate length and position of the vacuum supply port VSP are thuscorrelated with heat shrink process and extent of travel of the mandrelsFM (FM1) in the heat tunnel HT from the time the bottom blanks BD (DD1)are loaded on the said mandrels until sufficient shrinkage of thesidewalls SW1 (SW2) has been achieved to hold the said bottom blanks inplace.

Also provided in the fixed bottom disc VD2 is an ejection pressure portEPP fed from an ejection pressure supply source EPS. The ejectionpressure port EPP is positioned to time the application of positivepressure through vacuum ports VPR, vacuum hoses VH and vacuum ports VP(VP1) in the mandrels FM (FM1) to eject finished containers therefrom atthe ejection portion of the work station WS as will be more fullydescribed with reference to FIGS. 9 and 10.

Referring to FIGS. 7 and 9, a bank of work stations WS is shownincluding bottom blank loading, top curl forming, bottom sealing andejection functions.

As specifically shown in FIGS. 9 and 11; the chain carried mandrels FMare passed along a juxtaposed guide rail GR as they exit the heat tunnelHT at HT2.

The guide rail GR provides a thrust backing to cooperate with a bottomironing turret BIT having bottom irons BI in a radial array withperipheral spacing therebetween on the said turret corresponding to thespacing between adjacent finishing mandrels FM on the chain 46.

The bottom ironing turret BIT includes a rotating toroidal mounting BIMfor the bottom irons BI in which the latter are radially reciprocable. Acentral cam BIC is provided which constrains the bottom irons BI toengage with the bottom of formed cups or containers 100 on the finishingmandrels FM by means of cam follower wheels BIF and return springs BIS(FIG. 11).

Bottom sealing pressure is regulated by a compression spring BIP mountedin a telescoping section of the bottom iron BI in opposition to thereturn spring BIS to prevent the bottom irons BI from engaging thebottoms of the containers 100 on the mandrels FM with more than apredetermined maximum sealing force.

As shown in FIGS. 11A and 11B, th bottom iron BI is configured with araised annular boss BIA dimensioned to press into the inturned edgesSE1A of the sidewalls SW1 of the finished cups or container 100 on themandrel FM at a point at which the bottom blank BD is overlapped toenhance the seal therebetween and insure a liquid tight container bottomstructure.

Depending on the properties of the shrinkable foam material and bottomblank material the heat of the shrinking process may provide sufficientheat to form an annular heat seal on the bottom of the containers 100 orthe bottom irons BI can be heated to supply additional sealing heat.

As shown in the art other heating means, adhesives, solvents or the likemay also be used to enhance the ultimate bond between the inturnedportions SW1A (SW2A) of the sidewalls SW1 (SW2) of the containers 100and the bottom blanks BD (BD1).

A purely heat sealed bond is the preferred embodiment, however.

Referring to FIG. 10 in addition to FIG. 9, a top curl forming turretTCT is shown adjacaent to the bottom ironing turret BIT for receivingfinished cups or containers 100 ejected from the finishing mandrels FMand forming a top curl thereon, i.e., rolling the top rim outward onitself as is a well known preactice in the cup and container art.

The top curl turret TCT is shown as including a centrally located barrelcam TBC having a cam track TBC1 in which a plurality of follower rollersTFR ride to constrain vertical movement to respective ones of a likeplurality of vertical slides TVS on which are mounted radially disposedand outwardly opening cups receiving cavities TRC.

The barrel can TBC is coaxially and fixed mounted on the upper end of anon-rotating central shaft TCS for the turret TCT the said sahaft TCSbeing journaled through a hub assembly TRA which is mounted for relativerotation to the shaft TCS on a machine base plate MBP in bearing meansTRB.

The hub assembly TRA provides outboard slots for the vertical slidemembers TVS and an annular plate TRA1 beneath which a plurality ofradially disposed bearing means TRB1 are provided to receivereciprocating guide bars TGB for top curl forming tools TC mounted onein registry with each cup receiving cavity TRC on vertical bars TVB eachextending upward from respective guide bar TGB and a cam follower rollerTFRB engaging a cam track TPC1 in an annular plate cam TPC fixedlymounted on the machine base plate MBP.

Between the hub assembly TRA and the barrel cam TBC on the central shaftTCS is an annular kick-out cam TKO having a single kick-out rise TKR ata desired ejection station position TES (FIG. 9) to effect ejection ofthe containers 100 from the cavities TCR.

The kick-out cam TKO is engaged in the uppermost postions of thecontainer cavities TRC and vertial slides TVS by the inboard tips TEP1of ejection pin assemblies TEP which are spring biased to telescopicallyreciprocate in and out of the base of the container receiving cavitiesTRC to eject finish cups or containers 100 therefrom by a plunger actioninduced by the knock-out cam TKO.

Referring additionally to FIG. 1OA, the top curl tool TC is shown in the"IN" position as constrained by the plate cam TRC to cause mating topcurl forming surfaces TFG1 in the periphery of the cavities TRC and TFG2in the top curl tool TC to force the top of each container 100 into thecurled configuration 102 shown in FIG. 1OA and at the "IN" position ofthe top curl tool TC in FIG. 10.

Thus, in operation, rotation to the hub assembly TRA on the centralshaft TCS causes coordination vertical movement of the slides TVS andthe receiving cavities. TCR and radial movement of the curling tools TCto maximum height and radially outward positions, respectively, at the"OUT" position in FIG. 10 and minimum height and innermost radialpositions, respectively, at the "IN" position of FIG. 10.

This is effected by the coordination shapes of the cam tracks TBC1 andTPC1 on the barrel can TBC and plate cam TPC, respectively.

In the "OUT" positon of the top curl tool TC, the receiving chamber TCRis shown in FIGS. 9 and 10 as being indexed to receive a cup orcontainer 100 from the finishing mandrel FM as ejected therefrom bypositive pressure in the vacuum hose VH.

The hub assembly TRA rotates in synchronism with the travel of themandrels FM on the chain 46 and the receiving chambers TRC bearing acontainer 100 progress toward the "IN" position of FIGS. 9 and 10 inwhich the curling tool TC has been brought into juxtaposed registry withthe receiving cavity TRC to form the top curl 102 on the container 100(see FIG. 1OA).

Subsequently, the tool TC and the receiving cavity TRC separate rapidlyand the latter rapidly rises under control of the barrel cam TBC toengage the inboard end TEP1 of the ejection plunger TEP with thekick-out cam TKO and the ejection rise TKR thereon at the ejectionstation TES (see FIG. 9).

This ejects the containers 100 into engagement with an inverting detent104 in a magazine chute MAG such that the finished containers aremagazined in an upright position.

Prior to the placing of the cylinders 10C onto the finishing mandrels FM(FM1) a bottom blank or disc BD must be placed on the outboard end ofthe said mandrels to be held thereon by vacuum in the vacuum lines VHfrom the vacuum distributor VD as previously shown in FIGS. 6A, 6B, 8A,and 8B.

To accomplish this function, a supply of bottom blanks BD and a meansfor transferring them from the supply to the finishing mandrels FM (FM1)must be provided.

To this end, referring jointly to FIGS. 9 and 12, bottom strip stock BSSis fed to a rotary die roller BRD and anvil roll BAR to cause the dieroller to cut discs BD from the strip stock BSS and present it to abottom transfer plate BTP on a bottom transfer turret BTT adjacent tothe anvil roll BAR and indexed therewith to pick up each bottom disc BDas it is cut.

The bottom transfer plate BTP bearing the bottom disc BD is eventuallyindexed into registry with a passing finishing mandrel FM (FM1) andtransferred thereto.

The initial pick up of the bottom disc BD by the transfer plate BTP ismade by vacuum applied via a vacuum port BTV through vacuum distributorsBVD1 and BVD2.

The distributor BVD1 rotates with the bottom transfer plates BTP on theturret BTT while the distributor BVD2 remains stationary.

Vacuum is supplied through a vacuum hose BVH from a vacuum supply sourceBVS in the base of the turret BTT. The fitting of the hose BVH to thefixed distributor BVD2 acts as a valve to provide vacuum to the portsBTV at all locations via the distributors BVD1, BVD2 except at the righthand position shown in FIG. 12 for the bottom transfer plates BTP. Inthis position, there is no vacuum in the line BTV and the vacuum fromthe hose VH in the finishing mandrel FM, now coaxially indexed with thebottom transfer plate BTP will act to strip the bottom disc BD from theplate BTP and onto the base of the mandrel FM.

IN-LINE FILLING OF CONTAINERS AS THEY ARE MADE

As the finished containers 100 enter the magazine MAG at the ejectionstation TES of the top curl turret TCT, the containers can be fed, oneby one, as known in the art to diallike feeder discs 104 which areindexed by a shaft 106 to feed the containers 100, one-by-one to acontainer filling station 110 where food product 112 in a measuredamount is discharged into the container 100. The container 100 iselevated by a pedestal 108 to the filling station 110, which pedestalwithdraws to return the container to rest in the dial 104 on its topcurl 102.

The container 100 with food 112 is then transferred to another stationwhere a lid 114 is pressed onto the top curl 102 of the container 100 bya seating jig 116 as will now be described with reference to FIG. 14.

The jig 116 is provided with an ejection plunger 118 to eject the lidand container from the jig 116 after seating is completed. An air gap120 is maintained between the plunger 118 and the lid 114 in the eventthat vacuum is needed to initially retain the lid 114 in the jig 116.

A plurality of shaped pressure rollers 122 such as schematicallyillustrated, are spaced around the top curl 102 and produce a curvedseam 114R between the top curl 102 and the lid 114.

A pedestal 108A is utilized to transfer the filled container 100 fromthe dial 104 to the lid seating jig 116.

In an alterante embodiment for seating a lid 114A on a container 100A,having an uncurled top edge 102A, a top edge overlap 114RA on the lid114A is clinched in place by segmented jaws 124 in cooperation with aseating jig 116A. This embodiment is shown schematically in FIG. 15.

Rotary transfer dials 104 and pedestals 108 and filling stations 110such as those shown in FIG. 13 are known in the art.

For example, U.S. Pat. No. 3,225,899 for Machine For Packaging FoodProducts of J. B. West issued Dec. 28, 1965 and U.S. Pat. No. 3,345,801for Auxiliary Unit For Packaging Machine to J. B. West, issued October10, 1967 illustrate container filling, capping and handling machines ofthe type generally described with reference to FIGS. 13, 14 and 15.

With the present invention, cans and containers can be made as neededand no storage of completed containers is necessary in conjunction witha given canning or packaging run.

Only rolls of sidewall and bottom blank material need be stored toeffect a supply of containers for holding a given volume of foodproduct.

This also permits the use of non-nestable container shapes whichheretofore have been undesirable because of their bulk in an unfilledcondition. Once filled, of course, even nestable containers assume suchbulk in storage.

Thus, with the continuous container manufacturing method and means ofFIGS. 1-12, feeding the continuous filling and capping equipmenttypified by FIGS. 13-15, an extremely efficient operation is providedwhich requires only a minimum of warehouse space for the containersrequired.

SUMMARY OF CONTAINER MAKING OPERATION

As illustrated in FIGS. 1-3, foam plastic strip stock, stretch orientedon its length lOB, is cut into rectangular blanks 1OA and transferredtransversely of its length 10B through continuous folding means M, H1,H2, FR1, FR2 and a heat seaming means PB to form seamed cylinders 10Ccircumferentially stretch oriented.

The cylinders 10C are placed over finishing mandrels FM (FM1) havingbottom blanks BD already in place from a bottom transfer turret BTT(FIGS. 9, 12).

A chain drive 46 (FIGS. 1, 3, 7, 9) carries the mandrels FM (FM1)through a heat shrink tunnel causing the cylinders 10C to shrink andassume the shape of the mandrels FM (FM1) as shown in FIG. 6A/6B). Thesidewalls SW1 (SW2) shrink beneath the mandrels FM (FM1) to placeannular overlapping portions SW1A (SW2A) over the outer edges of thebottom disc BD (BD1) as further shown in FIG. 6A (6B).

As the mandrels FM (FM1) bearing shrink formed containers 100 leave theheat tunnel HT (FIGS. 7, 9, 10, 11) bottom seams are formed in theoverlap by bottom irons BI on a bottom ironing turret BIT in a mannermost specifically illustrated in FIGS. 11A, 11B.

The top curl 102 is then formed on the containers 100 by dischargingthem from the mandrels FM (FM1) into the receiving chambers TRC of thetop curl forming turret TCT which, as shown in FIG. 10A, places a topcurl 102 in each container 100 with top curl tool TC.

Subsequent to the forming of the top curl 102, the container 100 isejected from the top curl turret TCT at an ejection station TES,inverted to proceed bottom first into a magazine MAG and thus placed inreadiness for either packaging or for processing in filling equipment.

THE BOTTOM BLANK APPARATUS AND METHOD

FIGS. 16A and 18 illustrate a more detailed preferred embodiment of abottom blank handling apparatus for severing bottom blanks from a webfeed roll and tangentially transferring the bottom blanks to finalforming mandrels at a compatible velocity and spacing.

FIGS. 16A through 16C illustrate a top plan view of the detaileddisclosure of a bottom blank handling apparatus of the presentinvention. FIG. 16A illustrates a top plan view of the left-hand portionof the apparatus. FIG. 16B illustrates a top plan view of the centerportion of the apparatus. FIG. 16C illustrates a top plan view of theright-hand portion of the apparatus.

As illustrated in FIG. 16A through 16C, a bottom strip stock BSS is fedbetween the pinch rollers 201 and 202, around the stationary guide 203and is held against the outer surface of the anvil roll BAR. Thereafter,the bottom strip stock BBS passes between the rotary die roller BRD andthe anvil roll BAR where the bottom blanks BD are severed from thebottom strip stock. As illustrated in FIG. 16B, after the bottom blanksBD are severed from the bottom strip stock BSS the remaining scrapportion of the bottom strip stock is conveyed around the stationaryguide 204 and between the pinch rollers 202 and 205 to discharge thescrap material. In a preferred embodiment of the present invention, thepinch rollers 201, 202, and 205 are covered with a polyurethanematerial. The pinch rollers 201 and 202 pull the bottom strip stock froma roll of material to feed the web. Similarly, the pinch rollers 202 and205 pull the scrap bottom strip stock from between the rotary die BRDand the anvil roll BAR to discharge the scrap material.

The rotary die roller BRD is mounted in sliding bearing blocks so thatthe jack screws 230S may accurately position the rotary die adjacent thefirst transfer turrent or anvil BAR. Referring additionally to FIGS.17A, 17B, 17C and 18, the rotary die BRD includes five cutters CDpositioned around the circumference thereof. Further, the rotary dieincludes two bearing portions 241, 242 which are designed to engage camfollowers 231, 232 respectfively. The cam followers 231, 232 are mountedon a shaft 233 positioned in cam housing 234. Further, the rotary dieBRD includes outwardly projecting portions 243, 244 which are mounted inbearings 245, 246, respectively. The bearings 245, 246 are mounted onthe slidable bearing blocks 247, 248 which enable the rotary die to beprecisely positioned adjacent the first transfer turret or anvil BAR.

The sliding bearing block 247 includes an outwardly projecting portion247A which is slidably received between a flange of the framework F anda plate 249 which is secured to the framework F. As illustrated in FIG.18, the outer portion of the bearing 245 is securely positioned withinan opening in the sliding bearing block 247. The inner portion of thebearing 245 mates with the outwardly projecting portion 243 and isprecluded from axial movement by engagements with the flange 243F.Further, the bearing 245 is held in place by means of the plate 247Pwhich is secured to the sliding bearing block 247. To ensure thepositioning of the bearing 245 relative to the outwardly projectingportion 243 of the rotary die BRD a threaded nut 251 is positionedadjacent the lower end of the outwardly projecting portion 243. Further,as illustrated in FIGS. 17A and 18, a gear 252 is positioned adjacentthe lowermost portion of the outwardly projecting member 243 and issecured thereto by means of a key 252K and a bolt 252B.

The sliding bearing block 248 together with the housing portion 248Hslidably mates with the framework F at the uppermostportion of therotary die BRD. The outermost portion of bearing 246 is securelypositioned within the sliding bearing block 248. The innermost portionof the bearing 246 mates with the outwardly projecting portion 244 ofthe rotary die BRD. To ensure the positioning of the bearing 246relative to the rotary die BRD, a plate 248P is secured to the slidingbearing block 248. The plate 248P prevents avial movement of the bearing246.

Referring to FIGS. 17B and 18, in one embodiment of the presentinvention a compressed air supply 240CA may be supplied to the upperportion of the housing 248H of the sliding bearing block to facilitatethe transfer of a severed bottom blank BD from the bottom strip stockBSS and cutter CD to the peripheral surface of the first transfer turretor anvil BAR. The compressed air supply 240CA is securely threaded intothe upper surface of a compressed air housing 240H. The upper surface ofthe compressed air housing is firmly secured to the lower portion of thehousing. In this embodiment of the present invention, the lower portionof the housing is constructed of nylatron.

As illustrated in FIG. 17B, the compressed air housing is prevented fromrotation by means of a pin 240P. Further, the compressed air housing isspring biased downwardly by means of the spring 240S positioned withinthe upper portion of the housing 248H. The compressed air housing 240Hincludes an opening 240B disposed in the lowermost portion thereof whichcommunicates compressed air from the compressed air supply 240CA to aconduit 244C of the rotary die BDR. It should be noted, that theoutwardly projecting portion 244 includes five conduits 244C disposedlongitudinally therein which communicate compressed air to each of thecutting dies disposed around the circumference of the rotary die BRD.Since the compressed air housing 240H includes only one opening 240Bdisposed in the bottom portion thereof, compressed air is transmitted toone of the longitudinally disposed conduits 244C only when the diepositioned on the circumference of the rotary die BRD is in the processof severing a bottom blank BD from the bottom strip stock BSS. In otherwords, the compressed air is supplied to the rotary die to facilitatethe discharge of a bottom blank BD to the anvil BAR only after thebottom blank has been severed from the bottom strip stock BSS. Since thecompressed air housing 240H is keyed to the sliding bearing housing 248by means of a pin 240P, rotation of the compressed air housing isprohibited. Therefore, compressed air is only supplied when the opening240B and the longitudinally disposed conduit 244C are aligned asillustrated in FIG. 17B.

Although in one embodiment of the present invention compressed air maybe supplied to a compressed air housing 240H to facilitate the dischargeof a bottom blank BD to the anvil BAR, it should be understood that thepresent invention is not limited to this particular means of aiding thedischarge of the severed bottom blanks BD. FOr example, in the preferredembodiment of the present invention, illustrated in FIG. 16B, as thebottom strip stock BSS wraps around the rotary die BDR after the bottomblanks BD are severed therefrom, the resiliency of the bottom stripstock BSS actually pops the bottom blanks BD from the bottom strip stockto the anvil BAR.

Accurate positioning of the rotary die BRD adjacent the hardened anvilBAR is achieved by the cam followers 231, 232 mounted on the shaft 233within the cam housing 234. The cam housing 234 is slidably mountedadjacent the rotary die BRD. As previously discussed, the jack screws230S are threaded within openings in the framework F and engage the camfollowers housing 234. By rotating the jack screws 230S the camfollowers housing 234 is displaced towards the rotary die BRD. The camfollowers 231, 232 are likewise displaced against the bearings 241, 242to press the rotary die against the anvil BAR. Therefore, adjusting thejack screws 230S regulates the relative contact of the rotary die BRDagainst the anvil BAR to ensure proper die penetration of the bottomstrip stock BSS.

Referring to FIGS. 16B and 17B the first transfer turret or anvil BAR isillustrated as being mounted on an axle 260 being keyed thereto by themember 260K. The upper portion of the axle 260 is mounted in a bearing261 which is positioned in the framework F. The outermost end of theaxle 260 is secured to the bearing 261 by means of a screw nut 262.

The first transfer turret or anvil BAR has ten bottom blank stationspositioned around the circumference thereof. As illustrated in FIG. 17B,each station for receiving a bottom blank BD includes an "0" ring ORpositioned adjacent to the circumferential portion of the anvil BAR toeffect a better seal and permit a more accurate transfer. The "0" ringsare positioned adjacent to and concentric with the ends of the vacuumconduits 263C which are supplied with a source of vaccum conduits 263Cwhich are supplied with a source of vacuum by means of a manifold 266from a point prior to the severing of the bottom blanks BD from thebottom strip stock BSS by the rotary die BRD to a point immediatelyprior to the tangential transfer to the second trandfer turret BTT. The"0" rings OR are preferrably positioned in grooves by means of cement orthe like and project slightly outwardly from the peripheralcircumferential surface of the anvil BAR. As illustrated in FIG. 16B,the vacuum conduits 263C are supplied with a source of vacuum from apoint prior to the severing of the bottom blanks BD by the rotary dieBRD through an arc of approximately 180° until just prior to thetransfer of the bottom blanks BD to the second transfer turret BTT.

In a preferred embodiment of the present inveniton, the anvil BARincludes an upper portion 264 which may be constructed from steel.Further, the anvil includes a lower portion 265 which may be constructedof nylatron. The upper portion of the anvil 264 is keyed to rotate withthe axle 260. The lower portion of the anvil 265 is prevented fromrotating by means of the pin 267 which is inserted in the framework F.The lower portion of anvil 265 includes a manifold 266 positioned in theupper surface thereof so as to communicate the supply of vacuum to theconduits 263C between the pick-up point of the severed bottom blank BDadjacent the rotary die BRD to the tangential transfer of the bottomblank BD to the second transfer turret BTT. The lower portion of theanvil 265 includes a through opening 265A for venting the conduit 263Cto atmosphere at the time of tangential transfer of the bottom blank BDfrom the anvil turret BAR to the second transfer turret BTT.

A bearing 268 is secured to the framework F and mounted on the axle 260in a position beneath the anvil turret BAR. The bearing 268 is preventedfrom axial movement along the axle 260 because of the flange 260F.Further, a plate 260P is secured to the framework F and locks thebearing 268 in place relative to the axle 260 and the framework F.Further, a screw nut 269 is mounted on the axle 260 and ensures theproper positioning of the bearing 268 and the first transfer turret oranvil BAR.

A gear 270 is positioned on the axle 260 and keyed thereto by member270K. Further, a pulley take-off 271 is positioned on the axle 260 andkeyed thereto by member 271K. The gear 270 is spaced by element 272 fromthe pulley 271. Further, the pulley 271 is accurately positionedrelative to the gear 270 by means of a threaded nut 273. It should beunderstood that the pulley 271 is connected to the gear drive for thepinch rollers 201, 202 and 205.

A gear 274 is mounted on the axle 260 and is keyed thereto by theelement 274K. The gear is further secured to the axle 260 by the lockingscrew 275.

Referring to FIGS. 16A, and 17A the second transfer turret BTT is shownas including ten bottom blank holding stations positioned around thecircumference thereof and further includes an upper portion 280 and alower portion 281. The lower portion 281 is spring biased by element281S into engagement with the upper portion 280. In a preferredembodiment of the present invention the upper portion 280 may beconstructed of nylatron and the lower portion 281 may be constructed ofsteel.

The upper portion 280 of the second transfer turret BTT includes aplurality of conduits 280C which project upwardly and radiallyoutwardly. An "0" ring OR₁ is positioned adjacent to and concentric withthe ends of each conduit 280C to effect a better seal and permit a moreaccurate transfer. As illustrated in FIG. 16A, the conduits 280C are incommunication with a manifold or distributor 282 from the initialtangential pick-up of a bottom blank BD from the anvil BAR to a pointjust prior to the tangentail discharge of the bottom blank. The manifoldor distributor 282 is connected to a vacuum line 283 which supplies asource of vacuum to hold the bottom blank BD adjacent the secondtransfer turret BTT during a portion of its rotation.

As illustrated in FIG. 16A, the upper portion 280 of the second transferturret BTT includes a substantially flat peripheral area 280A on which abottom blank BD may be positioned. The "0" rings OR₁ are positioned oneat each of the areas 280A located around the circumference of the secondtransfer turret BTT adjacent to and concentrically with the ends of theconduits 280C to provide positive seals for enhancing the transfer ofthe blanks between turrets and ultimately to the mandrels FM. The "0"rings OR₁ are positioned by cementing or the like in annular surfacegrooves formed in the surface of the peripheral areas 280A and projectslightly outwardly therefrom. The peripheral areas 280A and the "0"rings OR₁ comprise the holding stations for the bottom blanks BD on theturret BTT.

The lower portion 281 of the second transfer turret includes a manifoldor distributor 282 positioned on a portion of the upper surface thereof.Further, the lower portion 281 includes a second manifold or distributor284 which is in communication with the conduits 280C at the tangentialdischarge point of the bottom blanks BD. The manifold 284 is thus ventedto atmosphere at the time of transfer to assure the transfer of thebottom blank BD from the second transfer turret to the final formingmandrel FM the latter being provided with a similar vacuum holding meansas illustrated in FIG. 16A.

The lower portion 281 is prevented from rotation relative to theframework F by means of a pin 285. Therefore, since the lower portion281 is held stationary and the upper portion 280 rotates about the axle287. The manifold or distributor 282 is accurately positioned tocommunicate the source of vacuum to the blank BD from the anvil BAR to apoint adjacent to the discharge of the bottom blanks. Further, holdingthe lower portion 281 stationary relative to the upper portion 280ensures the accurate alignment of the manifold or distributor 284 tovent the conduits 280C to atmosphere at the discharge point of thebottom blank BD from the second transfer turret BTT.

As illustrated in FIG. 17A, the upper portion of the manifold 280 ismounted on an axle 287 and is held stationary thereto by means of awasher 287S and threaded nut 287N. Further, the upper portion 280 of thesecond transfer turret BTT is positioned on a flange 287F whichaccurately positions the upper portion 280 relative to anvil BAR and thefinal forming mandrels FM.

The lower portion 281 of the second transfer turret BTT is mountedadjacent the axle 287 but is held stationary with respect thereto bymeans of the pin 285 which is positioned in a portion of the frameworkF. In addition, the axle 287 is mounted in bearing units 288 and 289which are securely positioned in the framework housing F₁. The frameworkhousing F₁ is secured to the framework F by a plurality of bolts B₁ andB₂ which prevent rotation of the framework housing F₁. A threaded nut290 is positioned on the axle 287 and accurately positions the axialdisplacement of the second transfer turret BTT relative to the frameworkF.

Positioned adjacent the lowermost portion of the axle 287 is a gear 291which is keyed to the axle by member 292. It should be noted, that thegear 291 is constructed to be the same size as the gear 274 and is inmeashing engagement therewith. Further, the lowermost end of the axle287 is coupled to a gear reducer which in turn may be coupled to acommon drive element which may supply power to the entire containerforming machine.

OPERATION OF THE PREFERRED EMBODIMENT

In the preferred embodiment of the apparatus and method for severing andtransferring bottom blanks from a web feed roll to a work station thebottom strip stock BSS is fed between the pinch rollers 201, 202, whichmay be covered with polyurethane, and tend to pull the bottom stripstock BSS (web) from the web roll. The bottom strip stock BSS is fedaround a stationary guide 203 and thereafter passes between an anvilturret BAR and a rotary die BRD where the cutter die CD severs a bottomblank BD from the bottom strip stock. The stationary guide 203 ispositioned so that the bottom strip stock BSS engages the peripheralsurface of the anvil BAR substantially before a bottom blank BD issevered therefrom. The manifold 266 is positioned so that the conduits263C are supplied with vacuum prior to the severing of the bottom blanksBD by the rotary die BRD. As the bottom strip stock BSS passes betweenthe anvil BAR and the rotary die BRD and begins to wrap around therotary die BRD after the bottom blanks BD are severed therefrom, theresiliency of the bottom strip stock BSS actually pops the bottom blanksBD from the bottom strip stock to the anvil BAR, in conjunction with thevacuum in the latter.

Thereafter, the scrap material is fed around the stationary guide 204and between the pinch roller 202, 205 which tend to pull the scrapmaterial from the bottom blank severing apparatus.

The rotary die BRD includes five cutters CD positioned around thecircumference thereof. Positioned adjacent the rotary die are twobearings 241, 242 which are engaged by cam followers 231, 232. The camfollowers are positioned in a cam follower housing 234 which is engagedby jack screws 230S. The jack screws are threaded in the framework F ofthe bottom blank cutting apparatus and may be tightened to axiallydisplace the cam follower housing 234 thereby exerting a force throughthe cam followers 231, 232 to the bearings 241, 242 to ensure proper diepenetration of the bottom strip stock. As discussed hereinabove, therotary die BRD and the cam follower housing 234 are slidably mounted onthe framework F. Therefore, tightening or loosening the jack screws 230Sactually displaces the cam follower housing 234 and the rotary disc BRDwith respect to the fixed anvil BAR.

The bottom blank BD is severed from the bottom strip stock BSS andtransferred from the rotary die BRD to the anvil turret BAR. Vacuum issupplied to the anvil turret BAR to aid in the positioning of the bottomstrip stock BSS on the anvil BAR and to aid in the transfer of thebottom blank BD and to retain the bottom blank on the circumferentialsurface of the anvil turret BAR through an arc of approximately 180°. An"0" ring OR is positioned adjacent to and concentric with the ends ofeach conduit 263C to effect a better seal and permit a more accuratetransfer.

The bottom blanks BD are tangentially transferred from the anvil turretBAR to the second transfer turret BTT. At the point and time oftangential transfer the vacuum supplied to the conduit 263 is vented tothe atmosphere by means of the opening 265A. The venting of the conduits263C permits the transfer of the bottom blanks BD from the anvil to thesecond transfer turret where the bottom blanks are retained onsubstantially flat peripheral areas 280A by means of a vacuum suppliedthrough conduits 280C. The bottom blanks BD are held on thecircumferential surface of the second transfer turret BTT through an arcof approximately 180° by means of the vacuum supplied through the vacuumline 283, the manifold or distributor 282 and the conduits 280C. Thevacuum supplied to the conduits 280C is terminated just prior to thetangential transfer of the bottom blanks BD from the second transferturret BTT to the final forming mandrels FM. At the point and time oftransfer of the bottom blank BD to the final forming mandrels FM theconduits 280C are vented to atmosphere to ensure the tangential transferof the bottom blanks BD to the final forming mandrels FM by means of thevacuum present in the latter which thereafter retains the bottom blankson the said mandrels.

Rotational power is supplied to the bottom blank severing apparatusthrough a gear reducer which is coupled to the axle 287. The gear 291 iskeyed to the axle 287 and rotates therewith. Further, the gear 274 iskeyed to the axle 260 and is in meshing engagement with the gear 291.Since the gear 274 is equal in size to the gear 291, the rotationalspeed of the anvil BAR IS equal to the rotational speed of the secondtransfer turret BTT. However, since the anvil BAR is approximatelyone-half the size of the second transfer turret BTT, the peripheralspeed of anvil turret BAR is less than the peripheral speed of thesecond transfer turret BTT. This permits the narrow spacing requirementsbetween the bottom blanks BD occasioned by the low scrap configurationof the rotary cutter BRD to be amplified to a compatible spacing withthe bottom blank holding stations on the circumferential surface of thesecond transfer turrett BTT. This ultimate spacing between the blanks BDand the peripheral velocity thereof on the circumferential surface ofthe second transfer turrett BTT is selected to be completely compatiblewith the spacing between and transitory velocity of the final formingmandrels FM. Thus, the cut blanks BD are fed continuously and accuratelyfrom a closely spaced, low scrap condition at a first velocity to anincreased spacing and second velocity compatible with the spacing andvelocity of the transitory finishing mandrels.

The gear 270 is keyed to the axle 260 and is in meshing engagement withthe gear 252. The size of the gear 252 and 270 are designed so that therotational speed of the rotary die BRD is approximately twice therotational speed of the anvil turret BAR and the second transfer turretBTT. As previously discussed, the rotary die BRD includes five cutterdies CD positioned around the circumference thereof while the anvilturret BAR has ten blank holding positions about its circumference. Thediameter of the rotary die is approximately one-half the diameter of theanvil and approximately one-fourth the diameter of the second transferturret, respectively. Therefore, since the rotational speed of therotary die BRD is approximately twice the rotational speed of the anvilBAR the cutter dies CD align with the greater number of bottom blankpositions spaced around the circumference of the anvil turret BAR andaccurately and tangentially transfer a bottom blank from the rotary dieto the anvil.

In summary, the bottom blank severing apparatus and method disclosed inthe present inveniton continuously supplies a bottom strip stock to arotary cutting die and effects a tangential transfer to a rotary anvil.Thereafter, the bottom blanks are tangentially transferred from theanvil to a second transfer turret. Subsequently, the bottom blanks arecontinuously tangentially transferred from the second transfer turret toa final forming mandrel FM which is supplied with vacuum to retain thebottom blanks thereon. The peripheral speed of the second transferturret BTT and spacing of the holding positions thereon are correllatedwith the transitory speed and spacing, respectively, of the finalforming mandrels FM which are positioned on a chain and are continuouslymoved past the transfer point for bottom blanks BD carried on thetransfer turret BTT. The mandrels subsequently and continuouslytranslate through a cylindrical blank transfer point, a bottom bangerassembly, a shrink oven, and a bottom iron.

Thereafter the finished containers on the mandrels FM are removed fromthe mandrels and may be processed through a top curl assembly and thenceout through a discharge chute to complete the container making process.

The Mandrel Assembly

FIGS. 19, 19A, 19B and 20 illustrate a more detailed preferredembodiment of the mandrel assembly of the present invention. Thismandrel assembly is adapted to receive the cylindrical blanks deliveredto the mandrel from the cylindrical blank forming assembly of FIGS. 1and 3. The cylindrical blank is later securely positioned upon themandrel assembly by a cylindrical blank tamper assembly to be laterdescribed in connection with FIGS. 21 and 22.

As illustrated in FIGS. 19, 19A, 19B and FIG. 20, a dual taperedfrustro-conical mandrel DTM is rotatably fixed to a mandrel supportshaft 302. The mandrel support shaft 302 is rigidly mounted on a mandrelcarrier 304. The mandrel carrier 304 is transferred between workstations by a pair of endless link chains 306, 308. A pair of stabilizerbars 307A, 307B are mounted on each mandrel DTM at the respectivemounting points of the pair of endless link chains 306, 308. Thesestabilizer bars 307A, 307B ride on the rollers of the endless linkchains 306, 308 to stabilize the movement of the respective mandrelsDTM. The mandrel DTM has an axial direction extending along the axis ofthe mandrel support shaft 302. Some of the operations performed on theblanks carried by the mandrel DTM require a force to be applied to themandrel in this axial direction. For example, a cylindrical tamperassembly (to be hereinafter described) applies an axial force on themandrel DTM to securely push the cylindrical blank onto the mandrel. Themandrel DTM is rigidly held against this force through the use of aforce restraining roller 310 rotatably mounted in a force restrainingroller bracket 312. This force restraining roller 310 is generallyrestrained by a metal guide track 314 shown by phantom lines. A metaltrack such as that exemplified by the metal guide track 314 is placed inthose areas of travel of the mandrel assembly where an axial force is tobe applied to the mandrel.

To further stabilize the mandrel during the transfer of a bottom blankBD from the bottom blank forming station BBF and the transfer of acylindrical blank 10C from the cylindrical blank forming station CBF astabilizer blade 309 is provided. During these critical transfers, thestabilizer blade 309 rides in guides (not shown) to further support andstabilize the mandrels DTM.

The dual tapered frustro-conical mandrel DTM is attached to a mandrelcoller 318. This mandrel collar 318 is supported by a mandrel supportbearing 316 which allows the mandrel DTM to freely rotate on the mandrelsupport shaft 302. The mandrel collar includes a mandrel rotationsurface 320 which rotates the mandrel DTM when the mandrel DTM is movedalong a mandrel rotation track 322 shown in phantom lines. Duringcertain steps of the cup making process it is desirable to rotate themandrel in order to, for example, achieve even heating across themandrel surface. When this rotation of the mandrel is desired, arotation track such as the exemplary mandrel rotation track 322 isplaced in a corresponding position along the mandrel assembly path inorder to rotate the mandrel. This mandrel rotation track 322 is made ofany desired material, in the preferred embodiment heat resistantsilicone rubber is used to provide the mandrel with sufficient tractionfor rotation. The mandrel collar may be made of any appropriatematerial, aluminum is used in the preferred embodiment.

One important feature of the dual tapered frustro-conical mandrel DTM ofthe present invention is the mandrel's dual taper. In the preferredembodiment, an upper two-thirds 324 of the mandrel DTM is formed with anapproximate taper of 7° while a lower one-third or smaller end 326 ofthe mandrel DTM is formed with an approximate taper of 9° 30". This dualtaper is an advantageous feature of the mandrel of the present inventionwhich aids in reducing the stack height of the cups formed by thepresent invention. The dual taper also prevents the stacked cups fromsticking together. Thus the dual tapered cups formed using the mandrelDTM of the present invention may be more easily used in applicationswhere a smooth separation of stacked cups is necessary, such as in a cupdispenser of a vending manchine.

Another important feature of the dual tapered frustro-conical mandrelDTM of the present invention is the ability of this mandrel to formscallop details along the lower edge of a cup's sidewall. FIG. 19A showsa detail of the end surface of the frustro-conical mandrel which shows aset of ten equally spaced scalloped indentations 328 formed along thelower edge of the lower one third 326 of the mandrel DTM. During theshrinkage of the cylindrical blank into a cup, a vacuum is applied tothe equally spaced scalloped indentations 328 through a set of scallopvacuum holes 330 to apply vacuum to the scalloped indentations 328during the shrinkage process in a manner which will be explained below.

A cylindrical blank is positively attached to the mandrel DTM of thepreferred embodiment through the use of a cylindrical blank securingclamp 332. This securing clamp includes a securing clamp cover 334, aplurality of arcuate shoe segments 336 and a garter spring 338. Upon theinsertion of a cylindrical blank the garter spring 338 allows theflanged arcuate shoe segments 336 to expand and thereby resilientlysecure the edge of the cylindrical blank. The cylindrical blank tamperassembly discussed below loads the cylindrical blanks onto thefrustro-conical mandrel DTM. This operation seats the cylindrical blankfully into the spring loaded flanged arcuate shoe segments 336. Thesesegments 336 retain the cylindrical blank on the mandrel DTM during theshrinking process. The shape and location of the flanged arcuate shoesegments in combination with the positioning of the radiant heaters aslater discussed cause the post expansion of the top portion of the cupto be uniform in thickness. This improves the ability of the curlerassembly to form a good top curl as will be later discussed.

The mandrel assembly of the preferred embodiment includes both internalvacuum and pressure lines. The mandrel carrier 304 has provided thereina vacuum fitting 355 for connection to a vacuum distributor VD of FIGS.8A, 8B by the hose VH. Vacuum is applied to the dual taperedfrusto-conical mandrel DTM through the vacuum distributor VD of FIGS.8A, 8B, and internal passages within the mandrel assembly. A pluralityof primary vacuum passages 356, 358, 360 are provided in the mandrelcarrier 304 and mandrel support shaft 302 for supplying main vacuum fromthe vacuum fitting 355. A plurality of passage plugs 340, 341, 355 sealthe primary vacuum passages 356, 358, 360 which provide vacuum to aplurality of cup bottom passages 348 located on a mandrel bottom vacuum350. These cup bottom vacuum passages 348 retain the bottom blank BD onthe flush planar surface of the mandrel bottom 350.

A secondary vacuum passage 346 supplies vacuum to the scallop vacuumholes 330 provided to pass vacuum to the equally spaced scallopedindentations formed on the frustro-conical mandrel DTM. A mandrel vacuumvalve MMV shown in FIGS. 19 and 19B, supplies vacuum to the secondaryvacuum passage 346 and thereby to the scallop vacuum holes 330 whendesired. The details of this vacuum valve are of any suitableconstruction known in the art and this will not be further described.The vacuum valve MMV is actuated through the use of a vacuum valve lever342 and a vacuum valve roller 344. When the vacuum valve roller 344 isdepressed by a cam (not shown), vacuum is applied to the scallop vacuumholes 330 and thus to the equally spaced scalloped indentations 328formed on the frustro-conical mandrel DTM. The cam used to operate themandrel vacuum valve, MMV is positioned to actuate this valve only afterthe cylindrical blank 1OC is shrunk to form a finished container (notshown here). If the scalloped indentations were to be formed before thecylindrical blank 10C was shrunk, the blank would wrinkle preventingproper shrinkage of the blank. Thus, secondary vacuum is applied to theequally spaced scalloped indentations 328 after the shrinkage process issubstantially completed and in the preferred embodiment, just before thebottom sealing operation is performed.

A compressed air system is also provided in the mandrel assembly of thispreferred embodiment. Compressed air is provided to the vacuum fitting355 from the vacuum distributor VD of FIGS. 8A, 8B. This compressed airis passed along the primary vacuum passages 356, 358, 360 to the cupbottom vacuum passages 348. To remove a cup from the mandrel DTM,compressed air is applied to the mandrel through the vacuum fitting 355and the primary vacuum passages 356, 358, 360. This compressed air ispassed through the cup bottom vacuum passages 348 in the mandrel bottom350 to eject the cup from the mandrel DTM.

The Cylindrical Tamper Apparatus and Method

FIGS. 21A, 21B and 22 illustrate a more detailed preferred embodiment ofa cylindrical tamper apparatus for securely positioning cylindricalblanks on the mandrel assembly of FIG. 19.

Prior to its arrival at the location of the cylindrical tamperapparatus, the mandrel DTM receives a cylindrical blank 10C from thecylinder forming apparatus of FIG. 1 of the present application. Whilethe pressure belt assembly PB translates the cylindrical blank 10Cforward onto the mandrel DTM, the cylindrical blank 10C is not usuallysecurely mounted by this operation. In order for the cylindrical blank10C to be securely fastened by the cylindrical blank securing clamp 332of the frustro-conical mandrel DTM, the cylindrical blank must besecurely seated into the spring loaded arcuate shoe segments 336 of thefrustro-conical mandrel DTM. The cylindrical blank must be securelyseated in order to keep the cylindrical blank from moving off themandrel DTM during the shrinking cycle.

The cylindrical tamper apparatus secures the cylindrical blank 10C ontothe frustro-conical mandrel DTM by pushing the cylindrical blank 10Cwith a tamper pad 370A. The tamper pad 370A is thrust against thecylindrical blank 10C by a tamper actuation assembly 372A. A pluralityof tamper actuation assemblies 372A-F with their associated tamper pads370A-F are provided on a revolving tamper turret 374. For the sake ofclarity, only one tamper pad 370A and its associated tamper actuationassembly 372A will be described, although other tamper pads 370B-F andtheir associated tamper actuation assemblies 372B-F are formed in anidentical manner. In a preferred embodiment of the present invention,five tamper pads and their associated actuation assemblies are used.While any number of tamper pads may be used, the circumferentialdistance between tamper pads should be approximately equal to thedistance between adjacent frustro-conical mandrels DTM as shown in FIG.22. These adjacent frustro-conical mandrels DTM are driven by the set ofendless link chains 306, 308 which move the mandrels along a mandrelmovement line MML.

A revolving tamper turret 374 is securely attached to a tamper turretshaft 375 by a tamper turret securing key 376. The tamper turret shaft375 is rotatably driven by a tamper chain drive generally indicated asTCD. The tamper chain drive drives the tamper assembly at a speed whichsynchronizes the circumferential speed of the plurality of tamper pads370A-F with the speed with which the frustro-conical mandrels DTM movealong the mandrel movement line MML. In a preferred embodiment, thefrustro-conical mandrels DTM move along the mandrel movement line MML ata speed of approximately 320 ft/min. Thus, the center of each of thetamper pads 370A-F also travels at a speed of approximately 320 ft/min

The tamper chain drive TCD derives its power from a lower left hand ovenshaft 377. A tamper oven sprocket 378 is fastened to the lower left handoven shaft 377 for positive rotation therewith. A tamper idler shaft 380is provided with a first intermediate drive sprocket 382 and a secondintermediate drive sprocket 384. The first and second intermediate drivesprockets 382, 384 are positively fastened onto the tamper idler shaft380 through the use of an idler shaft key 386. This idler shaft key 386insures that there is no slippage between the first and secondintermediate drive sprockets 382, 384. A drive reduction chain 388transfers power from the tamper oven sprocket 378 positively connectedto the lower left hand oven shaft 377 to the first intermediate drivesprocket 382 on the tamper idler shaft 380. The relative sizes of thetamper oven sprocket 378 and the first intermediate drive sprocket 382are determined by the desired final speed of the revolving tamper turret374 as discussed above. The idler shaft key 386 and the tamper idlershaft 380 serve to transfer the power supplied by drive reduction chain388 to the second intermediate drive sprocket 384. The secondintermediate drive sprocket 384 and the final drive chain 390 supplypower to a final drive sprocket 392 to rotate the revolving tamperturret 374 in synchronism with the passing of the frustro-conicalmandrels DTM along the mandrel movement line MML. Thus, the cylindricaltamper apparatus of this preferred embodiment is chain driven insynchronism with the movement of the frustro-conical mandrels DTM alongthe mandrel movement line MML.

The tamper actuation assembly 372A includes a tamper actuator sleeve 394securely fastened to the revolving tamper turret 374. A tamper push rod396 is slidably mounted within a cylindrical sleeve bore 398 formed inthe tamper actuator sleeve 394. The axis of the tamper push rod 396 isaligned so as to be parallel to the axis of the dual taperedfrustro-conical mandrel DTM and its mandrel support shaft 302. Thetamper pad 370A is mounted onto the end of the tamper push rod 396nearest the mandrel movement line MML.

A cup tamper spring 400 maintains the tamper pad 370A in its retractedposition as shown in FIG. 21A. The cup tamper spring is concentricallypositioned around the tamper push rod 396 and is supported by anactuator sleeve spring seat 406 formed on a tamper actuated sleeve 394.A biase force is applied to the tamper push rod 396 through a tampersplit collar 402 and a tamper spring retainer ring 404. The tamper pushrod 396 remains in its retracted position as biased by the cup tamperspring 400 unless a force is applied to the end of the tamper push rod396 opposite the tamper pad 370A through a tamper cam roller 408rotatably mounted on a tamper cam roller shaft 410. The tamper camroller 408 is affixed to a enlarged and flattened portion 412 of thetamper push rod 396 through which the tamper cam roller shaft 410 isfastened.

As the revolving tamper turret 374 rotates, the tamper actuator assembly372A also rotates. A stationary cam ring 414 is provided to create anaxial movement of the tamper pad 370. This stationary cam ring 414 ismounted on a stationary frame 416 and maintains the tamper actuationassembly 372A and its associated tamper pad 370A in a retracted stateduring approximately 270° of each tamper assembly's rotation. As thetamper assembly 372A approaches the mandrel movement line MML, thestationary cam ring 414 depresses the tamper push rod 396 by placing aforce on the tamper cam roller 408. This movement of the tamper push rod396 displaces the tamper pad 370A in a gradual manner. As thecircumferential direction of travel of each tamper assembly 372A-F andits associated tamper pad 370A-F approaches the direction of travel ofthe mandrels DTM along the mandrel movement line MML, the tamper pad 370becomes fully displaced by the stationary cam ring 414. In a preferredembodiment, the mandrel movement line is a tangent to a circle describedby the rotation of the center of each tamper pad 370 around the tamperturret shaft 375. At the point of tangency, each tamper pad 370A-F isfully depressed by its associated tamper actuation assembly 372A-F andthe stationary cam ring 414. The stationary cam ring 414 begins itsdepression of each tamper pad 370A-F and its associated tamper actuationassembly 372A-F when the tamper pad 370 is at an angle of approximately45° before the point of tangency. The stationary cam ring 414 continuesto depress the tamper pad 370 until it is fully depressed at the pointof tangency. The stationary cam ring 414 next allows the tamper pad 370to retract during the next approximate 45° of the rotation of revolvingtamper turret 374. The speed of the revolving tamper turret 374 issynchronized to the speed of the mandrels DTM along the mandrel movementline MML. The tamper pads 370 are positioned in such a way that thetamper pad 370 is fully depressed at the point of tangency at the momentwhen one of the mandrels DTM is also at the point of tangency.

As shown in FIG. 21A, the cylindrical tamper apparatus of the presentinvention seats the cylindrical blank onto the mandrel DTM.

In operation, the lower left hand oven shaft 377 supplies power to thetamper chain drive TCD which has a ratio which allows thesynchronization of the speed of the tamper pads 370A-F with the movementof the mandrels DTM along mandrel movement line MML. As the revolvingtamper turret 374 rotates on the tamper turret shaft 375, each tamperactuation assembly 372A-F controls the displacement of its associatedtamper pad 370A-F as directed by the stationary cam ring 414. Since themovement of each tamper actuation assembly 372A-F is synchronized to themovement of the frustro-conical mandrels DTM, at the point of tangency,between the mandrel movement line MML and the circle described by therevolution of the center of each tamper pad 370A-F these assemblies arecoaxially aligned. At this point of tangency, the stationary cam ringcauses the tamper pad 370A to be depressed by the tamper actuationassembly 372A. This places an axial force on a cylindrical blank alreadyplaced upon the frustro-conical mandrel DTM. This axial force securelyplaces the cylindrical blank onto the frustro-conical mandrel by forcingthe edge of the cylindrical blank already in contact with thefrustro-conical mandrel DTM into the cylindrical blank securing clamp332 as already described. This securely fastens the cylindrical blank tothe frustro-conical mandrel DTM and allows a uniform post expansion ofapproximately the top 3/8 inch of the cup.

The Curling Apparatus and Method

FIGS. 23, 24A, 24B and 25 illustrate a more preferred embodiment of thecurler apparatus of the present invention. This curler apparatus is amodification of the top curl forming station as illustrated in FIGS. 9and 10. Because of the similarity between this curling apparatus and thetop curl forming station of FIGS. 9 and 10, like elements will bedescribed using like identification descriptors.

In the preferred embodiment of FIG. 23, the curling apparatus isphysically removed from the chain drive 46 carrying the mandrels FM asshown in FIGS. 1, 3, 7 and 9. The containers 100 are transferred fromthe mandrels FM or DTM to a set of curling pots CP traveling along acurling pot drive chain 420. This curling pot drive chain 420 transmitsthe curling pots CP from a position from which these curling pots canaccept the finished containers 100 to a curling apparatus CCA. Thecurling pot drive chain 420 moves in synchronism with the movement ofthe mandrels FM or DTM on the chain 46 allowing each curling pot CP toaccept a finished container 100 ejected from the mandrel FM or DTM. Thecurling pots CP bearing containers 100 progress toward the curlingapparatus CCA. As each container 100 advances toward the curlingapparatus CCA, the upper edge of each container 100 is lubricated by acurling oil applicator apparatus as to be discussed later in relation toFIGS. 26 and 27 and 28. The curling apparatus CCA forms the top curl onthe containers 100 and these containers are ejected by timed air jetsprovided to the curling pots through a pair of dual cup blowoff lines422. Alternatively, only one single blow off line of sufficient capacityneed be used.

As illustrated in FIGS. 24A and B, a modified top curl forming turret isshown including a centrally located barrel cam TBC having a cam trackTBC1 in which a plurality of follower rollers TFR ride to constrainvertical movement to respective ones of a plurality of vertical curlingiron drive slides CID which are slidably mounted in a plurality ofcurling iron drive slide sleeves CSD. A plurality of driven curl formingirons or heated tools TC are each downwardly mounted on respectivecurling iron drive slides CID. In the preferred embodiment, each drivencurl forming iron TC is provided with a respective driven curling ironheater 424.

The barrel cam TBC is fixably mounted on a curling apparatus frame 426.A rotating central shaft 428 is coaxially mounted on a first and secondbearings 430, 432. A curling drive slide turret 434 is coaxially andfixably mounted on the rotating central shaft 428. The curling irondrive slide sleeves CSD are fixably mounted at equispaced distancesaround the periphery of the curling drive slide turret 434. Thus, inthis embodiment of the present invention, the curling iron drive slidesCID rotate around the barrel cam TBC which is stationary.

A first and a second curling pot drive chain sprockets 436,438 arecoaxially and fixably mounted on the rotating central shaft 428. Thesedrive chain sprockets 436,438 serve to guide the curling pot drive chain420 around the periphery of the curling apparatus CCA and rigidly locatethe curling pots CP in their respective desired positions to allowprecise interaction between a plurality of fixed curling anvils or die440, each integrally formed on a part of their respective curling potCP, and their associated driven curl forming irons TC.

Each of the curling pots CP located on the curling pot drive chain 420are provided with first and second curling pot positioning rollers442,444. As each curling pot approaches the curling apparatus CCA, thefirst curling pot positioning roller 442 enters an outside curling potrestraining track 446 which is channel-shaped in cross-section and ispositioned along the arc described by the travel of the curling pots CPabout the curling apparatus CCA. The second curling pot positioningroller 444 is likewise guided along an inside curling pot restrainingtrack 448 upon which the second curling pot positioning roller 444tracks as each curling pot CP is rotated around the curling apparatusCCA.

Each curling pot CP of the present invention includes a cup ejectorplunger 450 which is slidably mounted in an axial sleeve 452 provided ina curling pot body 454. A cup ejector plunger shaft 450A of each curlingpot CP is axially aligned with its associated curling iron drive slideCID. An axial air jet passage 456 is coaxially provided in the cupejector plunger shaft 450A. A cup ejector button 458 is provided at anend of the cup ejector plunger shaft 450A opposite the cup ejectorplunger 450. This cup ejector button has a hole provided therein whichforms a continuation of the axial air jet passage 456. The cup ejectorplunger 450 is spring biased by a cup ejector bias spring 460. This cupejector bias spring 460 and its associated spring seat 460A bias the cupejector plunger 450 in a retracted position.

A ramplike ejector button cam EBC serves to depress the cup ejectorbutton 458 and thus depress the cup ejector plunger 450 to loosen thefinished container 100 disposed within the curling pot body 454. As thecurling pots CP pass the dual cup blowoff lines 422, a blast of air isprovided by these lines through the axial air jet passage 456 within thecup ejector plunger 450 to eject the finished container 100 using ablast of air.

This blast of air is controlled by a cup eject air valve 462. Theemptied curling pots CP then continue around a large radius cam surfaceRCS which directs the curling pots towards the mandrel movement line MMLand then directs the curling pots along this mandrel movement line toallow acceptance of the finished containers 100 from the formingmandrels FM or DTM. A pair of idler sprockets IS1 and IS2 then directthe curling pot drive chain 420 and the curling pots CP attached theretoback towards the curling apparatus CCA. A large radius cam surface RCSmay be used instead of the pair of idler sprockets IS1, IS2 in order toreduce excessive vibrations which may result from the use of the idlersprockets during the high speed manufacturing process. An embodiment ofthe large radius cam surface is shown in FIG. 25.

FIG. 25 is a diagrammatic view of the curling apparatus CCA and alsoshows the large radius cam surface RCS and its redirection of thecurling pot drive chain 420. FIGS. 25A-D each show a diagrammatic detailof the fixed curling anvil 440, the driven curl forming iron TC, and thefinished container 100. Approximately 3/8' of the top rim of thefinished container 100 is a finished container edge portion 100A whichhas been securely held by the cylindrical blank securing clamp 332 ofthe frustro-conical mandrel DTM of the present invention. Because of theconstruction of the mandrel assembly, a uniform post expansion of thistop edge portion 100A of finished container 100 aids in the formation ofthe top curl 100B as shown in FIGS. 25C-D.

In operation, as the mandrels FM or DTM pass the curling apparatusstation, the curling pots CP are synchronized-48-herewith. The axes ofthe mandrels DTM and the curling pots CP are desirably colinear alongthis portion of the mandrel movement line MML. While the axes of themandrel DTM and the curling pots CP are colinear, compressed air isprovided to the compressed air fitting 354 of the dual taperedfrustro-conical mandrel DTM through the ejection pressure port EPP asshown in FIG. 8A. This compressed air is passed through the cup bottomvacuum passages 348 in the mandrel bottom 350 to eject the cup from themandrel DTM. This cup is ejected into a female cup receiving cavity FCRof the curling pot CP. As the curling pot drive chain 420 passes thecurling pot CP along a lower chain run between the large radius camsurface RCS and the curling apparatus CCA, the finished container 100 issecurely pressed into the cup receiving cavity of the curling pot CP anda top edge portion 100A of the finished container 100 has a thin coatingof the mineral oil applied thereto by the curling oil applicatorapparatus as discussed in FIGS. 26 and 27.

As the curling pot drive chain 420 moves the curling pot CP onto thecurling apparatus CCA, the first and second curling pot positioningrollers 442,444 are guided by the inside and outside curling potrestraining tracks 446,448 to securely mount the curling pot on thefirst and second curling pot drive chain prockets 436,438 to allow thecurling operation to be performed. At this time, the cylindrical blank100 is securely placed in the cup receiving cavity FCR of the curlingpot CP. As the curling pot rotates around the curling apparatus CCA, thedriven curl forming irons TC with their associated curling iron driveslides CID and curling iron drive slide sleeves CSD rotate insynchronism therewith on the curling drive slide turret 434. As thecurling iron drive slides CID rotate, the follower rollers TFR ride inthe stationary barrel cam TBC. This stationary barrel cam TBC controlsthe axial displacement of each driven curl forming iron TC as shown inFIGS. 25A-25D.

FIG. 25 shows the operation of the curling apparatus CCA in diagrammaticform. The curling pot CP becomes securely mounted on the curlingapparatus CCA at position zero as shown in FIG. 25. Position zero isapproximately at the point where the lower chain run of the curling potdrive chain 420 becomes approximately tangent to a circle described bythe first and second curling pot drive sprockets 436,438. As shown inFIG. 25A, the driven curl forming iron TC is retracted at position 0 ofFIG. 25. By the time the curling pot has reached position 1, the drivencurl forming iron TC has been advanced by the barrel cam TBC and thecurling iron drive slide CID to the position shown in FIG. 25B.Approximately 10° later, at position 2 of FIG. 25, the driven curlforming iron TC initially engages the upper edge of the top edge portion100A of the finished container 100. At this point curling begins asshown in FIG. 25C. The driven curl forming iron TC continues to advancetowards the fixed curling anvil 440 until the curl is complete atposition 3 as shown in FIG. 25D. Thus, the curling operation continuesfor approximately 108° of the rotation of the curling apparatus CCA andthe barrel cam TBC gradually advances the driven curl forming iron TCtowards the fixed curling anvil 440. The driven curl forming ironremains in position 3 for a rotational duration of approximately 27°.This curl dwell ensures that the curl is completely and properly made.The driven curl forming iron TC is then retracted by the curling irondrive slide CID and the barrel cam TBC. At position 4, where the upperchain run is approximately tangent to the circle described by the firstand second curling pot drive sprockets 436,438, the driven curl formingiron is sufficiently retracted to allow chain clearance for the exit ofthe finished cup in its associated curling pot CP. The drive curlforming iron TC continues to retract to its fully retracted positionwhere it remains until it again reaches position 0.

As the curling pot drive chain 420 guides the curling pot CP away fromthe curling apparatus CCA, the ejector button cam EBC applies a force tothe cup ejector button 548 to axially depress the cup ejector plunger450. This cup ejector cam EBC serves to break the seal between thefinished container 100 and the fixed curling anvil 440 created by thecurling process. The cups are then removed from the curling pots by theapplication of a jet of air applied to the axial air jet passage 456. Asshown in FIG. 23, the dual cup blowoff lines 422 apply a jet of air tothe axial air jet passages of adjacently disposed curling pots CP.Alternatively, a single blowoff line could be used. Packaging speedlimitations, may render it necessary to eject the cups two at a time,each to its own separate delivery system and to a packager (not shown).If packaging speed limitations are not a problem, a single blowoff lineand packaging system may be used. The timing of the air jet isaccomplished by the cup eject air valve 462 which synchronizes theapplication of the air jet to the positioning of the curling pots CP.

Curling Oil Applicator Apparatus and Method

Referring to FIGS. 26, 27 and 28, a detailed embodiment of a curling oilapplicator apparatus is disclosed according to the present invention.

The curling oil applicator apparatus is designed to lubricate the formedcontainers 100 which are each located in a respective curling pot CP. Aseach formed container 100 located in its respective curling pot CPpasses the curling oil applicator, one of a set of rotating lube brushes500, driven in synchronism with the curling pot CP, places a coating ofmineral oil onto the inside of the top edge of the formed container 100.

The curling oil applicator apparatus of the present invention includes,in the preferred embodiment, four (4) rotating lube brushes 500A-D. Eachof these rotating lube brushes 500A-D is fixably mounted to a respectivelube brush sprocket 502A-D. Each rotating lube brush 500A-D and itsassociated toothed lube brush sprocket 502A-D is lined with a lube brushbushing 503A-D which rotates on a respective lube brush shaft 504A-Dfixed in an associated lube brush shaft mount 506A-D. Each lube brushshaft mount 506A-D is attached to a respective lube brush retaining link508A--which forms a part of an endless roller chain 510.

The endless roller chain 510 is driven by a drive sprocket 512. An idlersprocket 514 is also provided to guide the endless roller chain 510along a desired path. The endless roller chain 510 resembles an ovalhaving its longitudinal axis parallel to the direction of travel of thecurling pots CP. The drive sprocket 512 is driven by a drive shaft 513keyed to the drive sprocket 512. The idler sprocket 514 rotates about anidler sprocket shaft 515 which is keyed to the idler sprocket 514.

An endless spur gear rack 516 is provided on a plane parallel to theplane parallel to a plane in which the endless roller chain 510 travels.The plane of the endless spur gear rack 516 is offset from the plane ofthe endless roller chain 510 to allow the toothed lube brush sprockets502 A-D to engage with the teeth of the endless spur gear rack 516. Thisendless spur gear rack 516 is shaped so as to allow the toothed lubebrush sprockets 502A-D to positively engage teeth of the endless spurgear rack 516 at all points along the endless roller chain 510.

A stationary cam 518 is mounted on an adjustable stationary cam bracket520 at a point midway between the drive sprocket 512 and the idlersprocket 514. This stationary cam 518 is provided to modify the run ofthe endless roller chain 510 adjacent to the passing curling pots CP ata point midway between the drive sprocket 512 and the idler sprocket514. This stationary cam allows this run of the rotating lube brushes500 A-D to be slightly arcuate, thereby aiding the entry of eachrotating lube brush 500 into the inner surfaces of the top edge portion100A of each finished container 100.

A lube applicator pad 522 is disposed within a lube applicator well 524.In the preferred embodiment, the lube applicator pad is advantageouslymade from an open cell foam rubber. The lube applicator pad ispositioned to provide oil to the ends of the individual fibers of therotating lube brushes 500A-D. The lube applicator pad 522 receives oilautomatically from an overhead gravity feeder. The oil automaticallystops flowing from this overhead gravity feeder if the machinery stops.

A first and a second lube brush restraining guides 526,528 are spaced ina parallel manner on both sides of the endless roller chain 510. Theserestraining guides 526,528 prevent the lube brush 500 and its associatedtooth lube brush sprocket 502 from drifting away from the endless spurgear rack 516 due to forces placed upon the rotating lube brush 500 byits contact with the top edge portion 100A of the finished container100. The first and second lube brush restraining guides 526 and 528restrain the rotating lube brush 500 by closely constraining the lubebrush shaft mount 506 which is formed with a substantially rectangularshape.

FIG. 28 is a plan view of the curling oil applicator apparatus of thepresent invention illustrating the details of a cup feeder wiper bladeand its associated wiper blade cam. A cup feeder plate 530 is positionedalong the line of travel of the curling pot CP. This cup feeder plate530 is placed at a distance from the position of each curling pot CP asit passes this cup feeder plate 530. The cup feeder plate 530 isprovided with an initial cup feeder ramp 531 which serves to initiallyguide the finished container 100 into the curling pot CP. The cup feederplate 530 is placed to allow the finished container 100 to be graduallypushed into the cup receiving cavity FCR of the curling pot CP. A cupfeeder wiper blade 532 is hingedly mounted on the cup feeder plate 530.A wiper blade bias spring 534 applies a bias force to the cup feederwiper blade 532. This bias force attempts to maintain this wiper bladeout of contact with the finished containers 100 as they pass. A wiperblade push rod 536 is connected to the cup feeder wiper blade 532. Awiper blade push rod cam roller 538 is affixed to the end of the wiperblade push rod 536 opposite to its point of connection on the cup feederwiper blade 532. A wiper blade cam 540 is affixed to the drive shaft 513for rotation therewith. In the preferred embodiment, this drive shaft513 rotates one revolution during the passing of each curling pot CP. Acam lobe 540A is provided on the periphery of the wiper blade cam 540.This cam lobe is positioned so as to depress the wiper blade push rod536 at the moment when one of the curling pots CP with its associatedfinished container 100 is directly under the cup feeder wiper blade 532.

The curling oil applicator apparatus of drawing FIGS. 26-28 is designedto be placed in the curler apparatus assembly along the lower run of thecurling pot drive chain 420 between the large radius cam surface RCS andthe curling apparatus CCA. In the preferred embodiment, the cup seaterplate 530 and the cup seater wiper blade 532 are positioned over theupstream edge portion of the large radius cam surface RCS.

In operation, the finished containers are removed from the mandrel FM orDTM by the application of a compressed air jet applied through the cupbottom vacuum passages 348 of the mandrel DTM. This jet of compressedair forces the finished container 100 off of the mandrel DTM and intothe curling pot CP. However, the finished container is not securelyseated at this point. As the curling pot CP containing the finishedcontainer 100 passes around the large radius cam surface RCS, the topedge portion 100A of the finished container 100 contacts the initial cupseater ramp 531 which insures that the cup is at least partially seatedwithin the cup receiving cavity of the curling pot CP by the forceprovided by this cup seating ramp 531. As the curling pot continues tomove, the contact between the cup seater plate 530 and the top edgeportion 100A of the finished container 100 insures that this container100 is aligned with the cup receiving cavity FCS of the curling pot CP.At the moment the curling pot CP nears the downstream end of the cupseater wiper blade 532, the wiper blade cam 540 and its associated wiperblade cam lobe 540A depresses the wiper blade push rod 536 to therebydisplace the cup seater wiper blade 532 to securely seat the finishedcontainer 100 into the cup receiving cavity FCR in the curling pot CP.The finished container 100 is then ready for the curling oil lubingprocess. Thus, the wiper blade assembly used in FIG. 28 securely seatsthe finished container 100 into the curling pot CP to allow the curlingoil applicator to apply an even coat of mineral oil around the inneredge of the top edge portion 100A of each finished container 100 as itpasses. The finished container 100 is also securely seated in order toallow an accurate curling operation to be performed on the cup.

The rotating lube brushes 500A-D of the curling oil applicator apparatusof the present invention are synchronized with the movement of thecurling pots CP past the curling oil applicator. As the curling pot CPapproaches the curling oil applicator, a rotating lube brush 500approaches the curling pot CP in synchronism therewith. Just prior tothe contact of the rotating lube brush 500 with the top edge portion100A of the finished container 100, a coating of mineral oil is appliedto the rotating lube brush 500 while this rotating lube brush 500 is incontact with the lube applicator pad 522. As the curling pot CPapproaches position A of FIG. 26, the rotating lube brush 500 begins toenter the top edge portion 100A of the finished container 100. The depthof insertion of the rotating lube brush 500 into the finished container100 may be controlled by adjusting the stationary cam 518 usingadjustable stationary cam bracket 520. It is this stationary cam 518which controls the movement of the rotating lube brush 500 into the topedge portion 100A of the finished container 100. As can be seen bypositions B and C, the endless roller chain 510 is guided along thestationary cam 518 to gradually insert the lube brush 500 into the topedge portion 100A of the finished container 100 until this lube brush isfully inserted. Because this lube brush is connected to the lube brushsprocket 502 which rotates on the endless spur gear rack 516, the lubebrush 500 continuously rotates as it moves in synchronism with themovement of the curling pot CP. After the curling pot CP and rotatinglube brush 500 move past the position of the stationary cam 518, thelube brush 500 is gradually removed from the finished container 100 in amanner similar to its entry into this container.

Thus, the inner surface of the top edge portion 100A of the finishedcontainer is coated with a light coating of mineral oil. This coating ofmineral oil aids in the curling process and results in an improvedfinished top curl around the upper edge of the finished container 100.The use of this curling oil applicator apparatus noticeably improves thequality of the top curl of each of the finished containers.

The Complete Cup Making Machine and Method

Referring to FIGS. 29 and 30, there is illustrated a detailed preferredembodiment of the complete cup making apparatus for producing completedfoam plastic containers from rectangular blanks of longitudinallystretch oriented foam sheet material.

Rather than use the arcuately disposed heat tunnel HT of FIG. 7, thepreferred embodiment of FIG. 29 utilizes radiant panel heaters which arenot covered by a sheet metal tunnel. As shown in FIG. 30, first andsecond shrink mandrel heaters 550,551 are used to preheat the mandrel FMor DTM of the present invention. As is the case with all the heatersused in the preferred embodiment and shown in FIG. 30, the shrinkmandrel preheaters 550, 551 have their wattage ratings noted on thedrawing. As shown in FIG. 30, the mandrel FM or DTM rotates as it passesthe first and second shrink mandrel preheaters 550, 551. This rotationis due to the interaction between the mandrel rotation surface 320 ofthe frusto-conical mandrel DTM and a mandrel rotation track 322 which isprovided along the length of the first and second shrink mandrelpreheaters 550,551.

Referring to FIG. 30, the first and second shrink mandrel radiantpreheaters 550,551 are illustrated as separated from the frustro-conicalmandrel FM or DTM at a distance of approximately 1".

A plurality of vertical run radiant heaters VRH are disposed along aleft vertical run of the mandrel movement line MML. The vertical runradiant heaters VRH include a first, a second and a third bottom heaters552-554 and a first, a second, and a third sidewall heaters 555-557. Inthe schematic cross-sectional view of FIG. 30, the separation betweenthe first and third sidewall heaters, the second bottom heater, and themandrel DTM is shown. In the preferred embodiment, both the bottomheaters 552-554 and sidewall heaters 555-557 are separated from themandrel DTM at a distance of approximately 1.5".

A set of horizontal radiant heaters HRH includes a first, a second, athird, and a fourth horizontal run bottom heaters 558, 559, 560, 561 anda first through a seventh horizontal run sidewall heaters 562-568. Inthe schematic cross-sectional view of FIG. 30A, the second and thirdsidewall heaters 563, 564 are separated from the mandrel DTM at aboutapproximately 1.5". Similarly, the second horizontal run bottom heater559 is also separated from the mandrel at approximately 1.5".

Throughout the vertical rise of the mandrels, DTM, a mandrel rotationtrack 322 is provided to rotate each mandrel DTM using the mandrelrotation surface 320. Similarly, throughout the horizontal travel of themandrel through the horizontal run radiant heat heaters HRH, the mandrelrotation track 322 is also provided to engage the mandrel rotationsurface 320 to rotate the mandrel DTM. This rotation is performed at allpoints where heat is applied to the mandrel to more evenly heat themandrel and the cylindrical blank mounted thereon. The first, second andthird bottom heaters of the vertical run radiant heaters VRH must be setto soften the bottom stock with a temperature that will not distort,shrink or curl it from its true round shape. At this point, the bottomis being held onto the mandrel bottom 350 by a vacuum applied to the cupbottom vacuum passages 348. The first three sidewall heaters 555-557 ofthe vertical run radiant heaters VRH must soften the cylindrical blankslightly, but not enough to curl it inward and cover the bottom disk BD.If the bottom disk BD is covered, the bottom will not fuse or heat sealbottom ironing turret BIT.

The horizontal run radiant heaters HRH are set at progressively highertemperatures with the last ones very high in order to finish theshrinkage and post expansion. These temperatures may need to be "tunedin" or adjusted slightly to suit the particular polystyrene foam sheetbeing run. Observation of the finished container 100 will inform one ofordinary skill in the art which of the heaters should be slightly raisedand lowered in heat to obtain a container that has good shrinkageappearance, but is not overheated or burned.

A sheet metal baffle 570 is provided over the horizontal run radiantheaters and on one side thereof to prevent cold drafts from blowing ontothe mandrels DTM.

The mandrels are preheated by the first and second shrink mandrelpreheaters 550,551 in order to keep the surface temperature of themandrels at the 170-180° F. temperature necessary for the properoperation of the cup-making process.

Referring to FIG. 29, the placement of the various assemblies alreadydiscussed into the completed cup-making apparatus of the presentinvention is further illustrated. An endless mandrel chain EMC carriesthe mandrels along the mandrel movement line MML which is formedsubstantially in the shape of a square. In the approximate center of thebottom of the square formed by the mandrel movement line MML, after eachmandrel DTM is preheated, the bottom blank BD is placed on the mandrelbottom 350 and held there by the cup bottom vacuum passages 348. Thisbottom blank BD is formed by the bottom blank forming station BBF whichforms this bottom blank BD and applies it to the mandrel bottom 350 asalready discussed in relation to FIGS. 16-18. As shown in FIGS. 1 and 3,the mandrel DTM then moves to the cylindrical blank forming station CBFwhich receives the rectangular blanks 10A from the rectangular blankcutting station RBC which feeds the rectangular blanks 10A to thecylindrical blank-forming station CBF. The cylindrical blank-formingstation places the cylindrical blank onto the mandrel DTM.

The mandrel then moves along the endless mandrel carrier chain ECM untilthe cylindrical blank tamper assembly CTA is reached. The cylindricalblank tamper assembly discussed in relation to FIGS. 21 and 22, securelyfastens the cylindrical blank onto the mandrel DTM. The mandrel with itsassociated cylindrical blank 10A and bottom blank BD is then transferredto the vertical run radiant heaters VRH and the horizontal run radiantheaters HRH which shrink the blanks to form a finished container 100.The bottom ironer assembly BIT then seals the seam between the bottomblank BD and the already shrunk cylindrical blank 10A. The mandrel DTMwith its associated finished container 100 then proceeds to a finishedcontainer pickoff point where the finished container 100 is removed fromthe mandrel DTM and deposited into a curling pot CP as alreadydiscussed.

The curling pots CP travel along a curling pot drive chain CPD whichcircles endlessly between the pickoff point from the endless mandrelchain drive EMC and the curling apparatus CCA. Each curling pot CPdisposed on the curling pot drive CPD then passes a curling oilapplicator COA which functions as already discussed in relation to FIGS.26-28. The curling pots CP are then received by the curling apparatusCCA which puts the top curl on the finished container 100 which is thenejected from the curling pot along the upper length of the curling potdrive chain CPD. Thereafter the finished containers are packaged fordistribution.

FIGS. 31 and 32 show an alternate preferred embodiment of the cup-makingapparatus and method of the present invention. This alternate embodimentis similar to the embodiment previously discussed except that a rotatingturret is substituted for the roller chain previously used to carry themandrels DTM.

Referring to FIGS. 31 and 32, a large rotating turret LRT is used in theplace of an endless mandrel carrying chain EMC and forty (40) mandrelsDTM are disposed along the periphery of the said large rotating turret.The mandrel assembly is substantially the same as that of previousembodiments except for its mounting structure on the rotatin turret LRT.Because of the change from the endless mandrel carrier chain EMC to thelarge rotating turret LRT, the vacuum lines necessary to apply vacuumand the air lines necessary to apply air to the mandrel DTM have beenmodified. Both the vacuum and air lines now distribute the vacuum andair from an air and vacuum distributor 600. This air and vacuumdistributor 600 distributes air to the individual mandrels DTM throughrigid air and vacuum lines, for example, a vacuum line 602. The largerotating turret LRT rotates on a turret shaft 604 which revolves in afirst and a second turret bearings 606,608. The turret is driven by aturret drive chain 610 which transfers power from a drive turret timingsprocket 612 to a turret power transfer sprocket 614. A cup tampertiming sprocket 616 and a bottom ironer timing sprocket 618 are providedon one end of the turret shaft 604 to transmit power and to synchronizethe movement of the bottom ironer BIT and the cup tamper assembly CTA.

Other than the above described modifications, the apparatus of FIGS. 31and 32 functions in a manner identical to that of the previousembodiments.

As each mandrel passes the first and second shrink mandrel preheaters550,551, a mandrel rotation track 322 engages the mandrel rotationsurface 320 of each mandrel DTM and rotates each mandrel DTM for evenpreheating. When the mandrel reaches the bottom blank forming apparatusBBF, a bottom disk BD is transferred to the mandrel bottom 350 where itis held by the cup bottom vacuum passages 348. The mandrel DTM thenmoves to the cylindrical blank transfer point where a cylindrical blankis placed on the mandrel DTM. The cylindrical tamper assembly CTA thensecurely fastens the cylindrical blank to the mandrel DTM. Duringapproximately 174° of the rotation of the large rotating turret LRT, thecylindrical blank and bottom disk are heated in a manner similar toprevious embodiments. During this entire process, the mandrel is rotatedby the interaction between the mandrel rotation surface 320 and amandrel rotation track 322. As the mandrel and finished container 100exit the oven section of the container-forming apparatus of thisembodiment, a bottom ironer BIT seals the seam between the bottom diskBD and the already shrunk cylindrical blank 10A to form the finishedcontainer 100.

This finished container is passed to the curling pot drive chain CPD ata finished container transfer point FCP. The finished container 100 thenhas its top edge portion 100A lubricated by the curling oil applicatorCOA and the curl is formed by the curling apparatus CCA. Thus, it can beseen that the embodiment of the present invention illustrated in FIGS.31 and 32 functions in a manner virtually identical to that of theprevious embodiment.

It should be understood that the apparatus and method for manufacturingpolystyrene foam containers of the present invention may be modified aswould occur to one of ordinary skill in the art without departing fromthe spirit and scope of the present invention.

What is claimed is:
 1. Means forming dual tapered containers fromrectangular sidewall blanks and disc shaped bottom blanks of shrinkablelongitudinally oriented thermoplastic sheet material comprising:conveyormeans feeding a plurality of longitudinally stretch oriented rectangularblanks along a predetermined path transversely of the longitudinaldimension thereof; cylindrical mandrel means positioned parallel withsaid predetermined path adjacent said conveyor means; folding meansadjacent said mandrel means over a portion of the length of the latterengaging and progressively folding said blank about said mandrel meanswhile feeding said blank along said path to overlap the ends thereof onsaid mandrel in the provision of a lapped seam; heating means adjacentsaid path for progressively applying heat to the ends of said blank toprepare said blank for heat sealing of said lapped seam; sealing meansadjacent said mandrel downstream of said folding means for pressing saidheated ends of said blank together to heat seal said lapped seam toprovide a cylindrical blank on said mandrel; a plurality of formingmandrels; mandrel movement means for sequentially indexing said mandrelsinto coaxial position with one end of said cylindrical mandrel meansalong a mandrel movement path; transfer means transferring saidcylindrical blanks from said blank forming means to said formingmandrels in synchronism with the indexing of the latter with the former;tamping means for securely pressing said cylindrical blanks onto saidmandrels to prevent possible slippage when said blanks are heated bysaid heating means, said tamping means including;a plurality of tamperpads; a stationary cam; a tamper actuation assembly operativelyconnected to each tamper pad including a cam follower tracking saidbarrel cam and transmitting the motion to said associated tamper pad;rotating head means for rotating each said tamper actuation assembly andassociated tamper pad along a rotary path different from said mandrelmovement path but in synchronism with the passing of said movingmandrels at a point of tangency between said paths; said cam displacingsaid tamper actuation assembly and associated tamper pad at said pointof tangency to push each cylindrical blank onto its respective mandrel;supply means for providing a plurality of disc-shaped bottom blanks forsaid containers sequentially indexed with said forming mandrels tosupply bottom blanks thereto; said final forming mandrels each includingat least a dual tapered sidewall and a bottom portion, respectively;means retaining said bottom blanks on said bottom portions of said dualtapered forming mandrels; heating means for heating said cylindricalblanks to a temperature sufficient to shrink said cylindrical blanksinto conformal engagement with said dual tapered sidewall portions andover the peripheries of said bottom blanks to form said dual taperedcontainers; said mandrel movement means moving said mandrels past saidheating means along a predetermined path; bottom ironing meansdownstream of said heating means for compressing the overlapped portionsof said sidewall and bottom blank to seal the bottom of said container;and discharge means ejecting said container from said mandrelsdownstream of said bottom ironing means.
 2. The invention of claim 1further comprising top curl forming means forming an annular rimconfiguration on a top rim portion of said containers to define mouthsof said containers.
 3. The invention of claim 2 further comprising lubemeans for applying a coating of lubricant to said top rim portion ofsaid containers prior to the formation of an annular rim configurationby said top curl forming means.
 4. The invention of claim 3 wherein saidmandrels are frusto-conical and dually tapered, said mandrels having anupper tapered portion and a lower tapered portion having a taper greaterthan that of said upper tapered portion.
 5. The invention of claim 4wherein said mandrels each include equally spaced scalloped indentationsformed in said tapered lower mandrel portion;said mandrel furtherincluding means for applying vacuum to said scalloped indentations toconform said blanks to the contour of said indentations.
 6. Theinvention of claim 3 wherein said heating means comprises a plurality ofradiant heaters.
 7. The invention of claim 6 wherein said mandrelmovement means also rotates said mandrels as they pass said heatingmeans to provide even heat distribution.
 8. The invention of claim 6wherein said mandrel movement means comprises an endless conveyor. 9.The invention of claim 6 wherein said mandrel movement means comprises arotating turret.
 10. The invention of claim 6 wherein at least some ofsaid radiant heaters are disposed along a substantially horizontalportion of said predetermined path;said heating means further comprisingbaffle means for blocking undesired drafts.
 11. The invention of claim10 wherein the radiant heaters along said predetermined path generateprogressively higher temperatures as their location nears the downstreamend of said heating means.
 12. Means forming containers from rectangularsidewall blanks and disc-shaped bottom blanks of shrinkablelongitudinally oriented thermoplastic sheet materialcomprising:cylindrical blank forming means for producing finishedcylindrical blanks having a longitudinal side seam and with saidorientation directed circumferentially of each said blank; a pluralityof mandrels; mandrel movement means for sequentially indexing saidmandrels into coaxial position with one end of said cylindrical mandrelmeans; transfer means transferring said cylindrical blanks from saidblank forming means to said forming mandrels in synchronism with theindexing of the latter with the former; supply means for providing aplurality of disc-shaped bottom blanks for said containers sequentiallyindexed with said forming mandrels to supply bottom blanks thereto; saidfinal forming mandrels each including at least a sidewall and a bottomportion, respectively; means retaining said bottom blanks on said bottomportions of said forming mandrels; heating means for heating saidcylindrical blanks to a temperature sufficient to shrink saidcylindrical blanks to conformal engagement with said sidewall portionsand over the peripheries of said bottom blanks to form said containers;said mandrel movement means moving said mandrels past said heating meansalong a predetermined path; bottom ironing means downstream of saidheating means for compressing the overlapped portions of said sidewalland bottom blank to seal the bottom of said container; lube means forapplying a coating of lubricant to substantially the entire said top rimportion of said containers prior to the formation of an annular rimconfiguration by said top curl forming means; said lube meanscomprising: a curling pot for holding said container; a gear rack; atleast one rotary applicator brush impregnated with a lubricant andhaving a gear coaxially mounted thereon; drive means for moving said atleast one applicator brush and its associated gear along said gear rackin synchronism with the movement of containers past said apparatus, saiddrive means having at least one shaft; said at least one applicatorbrush and its associated gear being rotatively mounted on said at leastone shaft to rotate when moved along said gear rack; and cam means forgradually displacing said at least one applicator brush into the top rimportion of said container to lubricate said top rim portion of saidcontainer, top curl forming means forming an annular rim configurationon a top rim portion of said containers to define mouth of saidcontainer; and discharge means ejecting said container from saidmandrels;
 13. The invention of claim 12 further comprising tamper meansfor securely pressing said cylindrical blanks onto said mandrels toprevent possible slippage when said blanks are heated by said heatingmeans.
 14. The invention of claim 13 wherein said mandrels arefrustro-conical and dually tapered, said mandrels having a upper taperedportion and a lower tapered portion having a taper greater than that ofsaid upper tapered portion.
 15. The invention of claim 12 wherein saidmandrels each include equally spaced scalloped indentations formed insaid tapered lower mandrel portion;said mandrel further including meansfor applying vacuum to said scalloped indentations to conform saidblanks to the contour of said indentations.
 16. The invention of claim12 wherein said heating means comprises a plurality of radiant heaters.17. The invention of claim 16 wherein said mandrel movement means alsorotates said mandrels as they pass said heating means to provide evenheat distribution.
 18. The invention of claim 16 wherein said mandrelmovement means comprises an endless conveyor.
 19. The invention of claim16 wherein said mandrel movement means comprises a rotating turret. 20.The invention of claim 16 wherein at least some of said radiant heatersare disposed along a substantially horizontal portion of saidpredetermined path;said heating means further comprising baffle meansfor blocking undesired drafts.
 21. The invention of claim 20 wherein theradiant heaters along said predetermined path generate progressivelyhigher temperatures as their location nears the downstream end of saidheating means.
 22. Means forming containers from rectangular sidewallblanks and disc-shaped bottom blanks of shrinkable longitudinallyoriented thermoplastic sheet material comprising:cylindrical blankforming means for producing finished cylindrical blanks having alongitudinal side seam and with said orientation directedcircumferentially of each said blank; a plurality of mandrels; arotating turret for sequentially indexing said mandrels into coaxialposition with one end of said cylindrical mandrel means; transfer meanstransferring said cylindrical blanks from said blank forming means tosaid forming mandrels in synchronism with the indexing of the latterwith the former; supply means for providing a plurality of disc-shapedbottom blanks for said containers sequentially indexed with said formingmandrels to supply bottom blanks thereto; said final forming mandrelseach including at least a sidewall and a bottom portion, respectively;means retaining said bottom blanks on said bottom portions of saidforming mandrels; heating means for heating said cylindrical blanks to atemperature sufficient to shrink said cylindrical blanks to conformalengagement with said sidewall portions and over the peripheries of saidbottom blanks to form said containers; said mandrel movement meansmoving said mandrels past said heating means along a predetermined path;bottom ironing means downstream of said heating means for compressingthe overlapped portions of said sidewall and bottom blank to seal thebottom of said container; lube means for applying a coating of lubricantto substantially the entire said top rim portion of said containersprior to the formation of an annular rim configuration by said top curlforming means; said lube means comprising: a curling pot for holdingsaid container; a gear rack; at least one rotary applicator brushimpregnated with a lubricant and having a gear coaxially mountedthereon; drive means for moving said at least one applicator brush andits associated gear along said gear rack in synchronism with themovement of containers past said apparatus, said drive means having atleast one shaft; said at least one applicator brush and its associatedgear being rotatively mounted on said at least one shaft to rotate whenmoved along said gear rack; and cam means for gradually displacing saidat least one applicator brush into the top rim portion of said containerto lubricate said top rim portion of said container, top curl formingmeans forming an annular rim configuration on a top rim portion of saidcontainers to define mouth of said containers; and discharge meansejecting said container from said mandrels downstream of said bottommoving means.
 23. The invention of claim 22 further comprising tampermeans for securely pressing said cylindrical blanks onto said mandrelsto prevent possible slippage when said blanks are heated by said heatingmeans.
 24. The invention of claim 22 wherein said mandrels arefrustro-conical and dually tapered, said mandrels having an uppertapered portion and a lower tapered portion having a taper greater thanthat of said upper tapered portion.
 25. The invention of claim 22wherein said mandrels each include equally spaced scalloped indentationsformed in said tapered lower mandrel portion;said mandrel furtherincluding means for applying vacuum to said scalloped indentations toconform said blanks to the contour of said indentations.
 26. Theinvention of claim 22 wherein said heating means comprises a pluralityof radiant heaters.
 27. The invention of claim 22 wherein said mandrelmovement means also rotates said mandrels as they pass said heatingmeans to provide even heat distribution.
 28. The invention of claim 22wherein said mandrel movement means comprises an endless conveyor. 29.The invention of claim 22 wherein said mandrel movement means comprisesa rotating turret.
 30. The invention of claim 22 wherein at least someof said radiant heaters are disposed along a substantially horizontalportion of said predetermined path;said heating means further comprisingbaffle means for blocking undesired drafts.
 31. The invention of claim30 wherein the radiant heaters along said perdetermined path generateprogressively higher temperatures as their location nears the downstreamend of said heating means.
 32. The invention of claim 20 or 22 whereinsaid baffle means extends above the entire area occupied by said radiantheaters, said baffle means substantially preventing convection losses.